Dodge - Caliber Srt 4 - Workshop Manual - 2007 - 2007

Factory Workshop Manual Make Dodge Model Caliber Srt-4 Engine and year L4-2.4L Turbo VIN F (2007) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations Alarm Module: Locations Component ID: 156 Component : MODULE-INTRUSION TRANSCEIVER Connector: Name : MODULE-INTRUSION TRANSCEIVER C1 Color : BLACK # of pins : 6 Pin Description Circuit 1 FUSED B(+) (I.O.D.) A415 20RD/TN 2-3 CAN B BUS (+) D55 20WT/OR 4 CAN B BUS (-) D54 20WT/PK 5 SIREN SIGNAL CONTROL D96 20WT/BR 6 GROUND Z941 20BK/WT Component Location - 41 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 7 Component Location - 43 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 8 Connector: Name : MODULE-INTRUSION TRANSCEIVER C2 Color : BLACK # of pins : 3 Pin Description Circuit 1-2 COURTESY LAMPS DRIVER M24 20YL/WT 3 GROUND Z941 20BK/WT Component Location - 41 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 9 Component Location - 43 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 10 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 11 Alarm Module: Diagrams Component ID: 156 Component : MODULE-INTRUSION TRANSCEIVER Connector: Name : MODULE-INTRUSION TRANSCEIVER C1 Color : BLACK # of pins : 6 Pin Description Circuit 1 FUSED B(+) (I.O.D.) A415 20RD/TN 2-3 CAN B BUS (+) D55 20WT/OR 4 CAN B BUS (-) D54 20WT/PK 5 SIREN SIGNAL CONTROL D96 20WT/BR 6 GROUND Z941 20BK/WT Component Location - 41 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 12 Component Location - 43 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 13 Connector: Name : MODULE-INTRUSION TRANSCEIVER C2 Color : BLACK # of pins : 3 Pin Description Circuit 1-2 COURTESY LAMPS DRIVER M24 20YL/WT 3 GROUND Z941 20BK/WT Component Location - 41 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 14 Component Location - 43 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 15 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Component ID: 161 Component : MODULE-SENTRY KEY REMOTE ENTRY/WCM Connector: Name : MODULE-SENTRY KEY REMOTE ENTRY/WCM Color : BLACK # of pins : 8 Pin Description Circuit 1 IGNITION SWITCH SENSE G20 20VT/BR 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4 GROUND Z937 20BK/YL 5 FUSED B(+) (I.O.D.) A411 20RD/LG 6 CAN B BUS (+) D55 20WT/OR 7 CAN B BUS (-) D54 20WT/PK 8-Component Location - 28 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 19 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 20 Keyless Entry Module: Diagrams Component ID: 161 Component : MODULE-SENTRY KEY REMOTE ENTRY/WCM Connector: Name : MODULE-SENTRY KEY REMOTE ENTRY/WCM Color : BLACK # of pins : 8 Pin Description Circuit 1 IGNITION SWITCH SENSE G20 20VT/BR 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4 GROUND Z937 20BK/YL 5 FUSED B(+) (I.O.D.) A411 20RD/LG 6 CAN B BUS (+) D55 20WT/OR 7 CAN B BUS (-) D54 20WT/PK 8-Component Location - 28 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 21 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Description and Operation > Description Keyless Entry Module: Description and Operation Description DESCRIPTION When a PCM and the SKREEM are replaced at the same time, perform the following steps in order: 1. Program the new PCM. 2. Program the new SKREEM. 3. Replace all ignition keys and program them to the new SKREEM. The Sentry Key REmote Entry Module (SKREEM) is sometimes referred to as the Wireless Control Module (WCM). The SKREEM/WCM is the primary component of the Sentry Key Immobilizer System (SKIS). It is also the receiver for the Remote Keyless Entry (RKE) system and the Tire Pressure Monitor (TPM) system. The SKREEM/WCM is located on the steering column, around the ignition lock cylinder housing and is concealed beneath the steering column shrouds. The molded black plastic housing for the SKREEM/WCM has an integral molded plastic halo-like antenna ring (3) that extends from one side. When the SKREEM/WCM is properly installed, the antenna ring is oriented around the ignition lock cylinder housing. A single connector (4) is located next to the antenna ring on the SKREEM/WCM housing (3). A molded plastic mounting tab (2) on the SKREEM/WCM housing secures the unit to the steering column. The SKREEM/WCM is connected to the vehicle electrical system through the instrument panel wire harness. The SKREEM/WCM cannot be adjusted or repaired. If faulty or damaged, the entire SKREEM unit must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Description and Operation > Description > Page 24 Keyless Entry Module: Description and Operation Operation OPERATION The Sentry Key REmote Entry Module (SKREEM), sometimes referred to as the Wireless Control Module (WCM), contains a Radio Frequency (RF) transceiver and a microprocessor. The SKREEM/WCM transmits RF signals to, and receives RF signals from the Sentry Key transponder through a tuned antenna enclosed within the molded plastic antenna ring integral to the SKREEM/WCM housing. If this antenna ring is not mounted properly around the ignition lock cylinder housing, communication problems between the SKREEM/WCM and the transponder may arise. These communication problems will result in Sentry Key transponder-related faults. The SKREEM also serves as the Remote Keyless Entry (RKE) RF receiver and, if the vehicle is so equipped, the receiver for the Tire Pressure Monitoring (TPM) system. The SKREEM/WCM communicates over the Controller Area Network (CAN) data bus with the Electromechanical Instrument Cluster (EMIC) (sometimes referred to as the Cab Compartment Node (CCN), the Powertrain Control Module (PCM), and/or the diagnostic scan tool. The SKREEM/WCM retains in memory the ID numbers of any Sentry Key transponder that is programmed into it. A maximum of eight Sentry Key transponders can be programmed into the SKREEM/WCM. For added system security, each SKREEM/WCM is programmed with a unique Secret Key code. This code is stored in memory, sent over the CAN data bus to the PCM, and is encoded to the transponder of every Sentry Key that is programmed into the SKREEM/WCM. Therefore, the Secret Key code is a common element that is found in every component of the Sentry Key Immobilizer System (SKIS). Another security code, called a PIN, is used to gain access to the SKREEM/WCM Secured Access Mode. The Secured Access Mode is required during service to perform the SKIS initialization and Sentry Key transponder programming procedures. The SKREEM/WCM also stores the Vehicle Identification Number (VIN) in its memory, which it learns through a CAN data bus message from the PCM during SKIS initialization. NOTE: After a SKREEM/WCM is replaced, the ignition/transponder keys need to be programmed to the new SKREEM/WCM. Follow the directions on the diagnostic scan tool. The transponder key for the SKREES/SKIM and the RKE will both be programmed during this operation. There is no need to program the fob of the key for RKE functionality once the transponder key is programmed to the new SKREEM/WCM. In the event that a SKREEM/WCM replacement is required, the Secret Key code can be transferred to the new SKREEM/WCM from the PCM using the diagnostic scan tool and the SKIS initialization procedure. Proper completion of the SKIS initialization will allow the existing Sentry Keys to be programmed into the new SKREEM/WCM so that new keys will not be required. In the event that the original Secret Key code cannot be recovered, SKREEM/WCM replacement will also require new Sentry Keys. The diagnostic scan tool will alert the technician during the SKIS initialization procedure if new Sentry Keys are required. When the ignition switch is turned to the On position, the SKREEM/WCM transmits an RF signal to the transponder in the ignition key. The SKREEM/WCM then waits for an RF signal response from the transponder. If the response received identifies the key as valid, the SKREEM/WCM sends a valid key message to the PCM over the CAN data bus. If the response received identifies the key as invalid or if no response is received from the key transponder, the SKREEM/WCM sends an invalid key message to the PCM. The PCM will enable or disable engine operation based upon the status of the SKREEM/WCM messages. It is important to note that the default condition in the PCM is an invalid key; therefore, if no message is received from the SKREEM/WCM by the PCM, the engine will be disabled and the vehicle immobilized after two seconds of running. The SKREEM/WCM also sends security indicator status messages to the EMIC/CCN over the CAN data bus to tell the EMIC/CCN how to operate the security indicator. The security indicator status message from the SKREEM/WCM tells the EMIC/CCN to turn the indicator on for about three seconds each time the ignition switch is turned to the On position as a bulb test. After completion of the bulb test, the SKREEM/WCM sends security indicator status messages to the EMIC/CCN to turn the indicator off, turn the indicator on, or to flash the indicator on and off. If the security indicator flashes or stays on solid after the bulb test, it signifies a SKIS fault. If the SKREEM/WCM detects a system malfunction and/or the SKIS has become inoperative, the security indicator will stay on solid. If the SKREEM/WCM detects an invalid key or if a key transponder-related fault exists, the security indicator will flash. If the vehicle is equipped with the Customer Learn transponder programming feature, the SKREEM/WCM will also send messages to the EMIC/CCN to flash the security indicator whenever the Customer Learn programming mode is being utilized. The SKIS performs a self-test each time the ignition switch is turned to the On position, and will store fault information in the form of a Diagnostic Trouble Code (DTC) in SKREEM/WCM memory if a system malfunction is detected. The SKREEM/WCM can be diagnosed, and any stored DTC can be retrieved using a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Description and Operation > Page 25 Keyless Entry Module: Testing and Inspection REMOTE KEYLESS ENTRY MODULE The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic information. Refer to the appropriate wiring information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Removal Keyless Entry Module: Service and Repair Removal REMOVAL NOTE: The steering wheel does not have to be removed to service the SKREEM/WCM. NOTE: The Steering Column Control Module (SCCM) assembly, which consists of the left/right multi-function switches and the clockspring, does not have to be removed to service the SKREEM/WCM. There is an access hole in the top of the right multi-function switch to access the mounting screw (2). 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. 2. Remove the upper and lower steering column shrouds. 3. Remove the SKREEM/WCM mounting screw (2) on the ignition lock assembly and separate the SKREEM/WCM (3) from the ignition lock assembly. 4. Disconnect the SKREEM/WCM electrical connector (4). 5. Remove SKREEM/WCM (1 and 3) from column (2). When a PCM and the SKREEM/WCM are replaced at the same time, perform the following steps in order. - Program the new PCM. - Program the new SKREEM/WCM. - Replace all ignition keys and program them to the new SKREEM/WCM. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Removal > Page 28 Keyless Entry Module: Service and Repair Installation INSTALLATION When a PCM and the SKREEM/WCM are replaced at the same time, perform the following steps in order. - Program the new PCM. - Program the new SKREEM/WCM. - Replace all ignition keys and program them to the new SKREEM/WCM. 1. Position the SKREEM/WCM (3) on the ignition lock housing and install the retaining screw (2). 2. Connect the SKREEM/WCM electrical connector (4). NOTE: On vehicles equipped with the optional Sentry Key Immobilizer System (SKIS), when the SKREEM is replaced with a new unit, a diagnostic scan tool MUST be used to initialize the new SKREEM and to program at least two Sentry Key transponders before the vehicle can be operated. 3. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Diagrams Navigation Module: Diagrams Component ID: 164 Component : MODULE-TRAFFIC INFORMATION RECEIVER Connector: Name : MODULE-TRAFFIC INFORMATION RECEIVER Color : # of pins : 12 Pin Description Circuit 1-2 CAN B BUS (+) D55 20WT/OR 3-4-5-6 FUSED B(+) (I.O.D.) A413 20RD/LB 7 GROUND Z909 20BK 8 CAN B BUS (-) D54 20WT/PK 9-10 - 11 - 12 - - Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations Voice Activation Module: Locations Component ID: 152 Component : MODULE-HANDS FREE Connector: Name : MODULE-HANDS FREE Color : DK. GRAY # of pins : 22 Pin Description Circuit 1 FUSED B(+) (I.O.D.) A417 18RD/DG 2-3-4 CAN B BUS (-) D54 20WT/PK 5 MICROPHONE 2 IN (+) X722 20LB/DG 6-7-- 8 LEFT AUDIO OUTPUT X703 22DG/OR 9 RIGHT AUDIO OUTPUT X704 22DG/PK 10 COMMON AUDIO OUTPUT X795 22DG/BK 11 - 12 - 13 - 14 CAN B BUS (+) D55 20WT/OR 15 VOICE RECOGNITION/PHONE SWITCH SIGNAL X730 20GY/YL 16 MICROPHONE 1 IN (+) X712 20DG/LB 17 MICROPHONE IN (-) X792 20LB/TN 18 - 19 - 20 MICROPHONE FEED X793 20DG/YL 21 SENSOR GROUND X835 20OR/BK 22 GROUND Z937 18BK/YL Component Location - 23 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations > Page 35 Fig. 23 Component Location - 24 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations > Page 36 Component Location - 26 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations > Page 37 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations > Page 38 Voice Activation Module: Diagrams Component ID: 152 Component : MODULE-HANDS FREE Connector: Name : MODULE-HANDS FREE Color : DK. GRAY # of pins : 22 Pin Description Circuit 1 FUSED B(+) (I.O.D.) A417 18RD/DG 2-3-4 CAN B BUS (-) D54 20WT/PK 5 MICROPHONE 2 IN (+) X722 20LB/DG 6-7-- 8 LEFT AUDIO OUTPUT X703 22DG/OR 9 RIGHT AUDIO OUTPUT X704 22DG/PK 10 COMMON AUDIO OUTPUT X795 22DG/BK 11 - 12 - 13 - 14 CAN B BUS (+) D55 20WT/OR 15 VOICE RECOGNITION/PHONE SWITCH SIGNAL X730 20GY/YL 16 MICROPHONE 1 IN (+) X712 20DG/LB 17 MICROPHONE IN (-) X792 20LB/TN 18 - 19 - 20 MICROPHONE FEED X793 20DG/YL 21 SENSOR GROUND X835 20OR/BK 22 GROUND Z937 18BK/YL Component Location - 23 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations > Page 39 Fig. 23 Component Location - 24 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations > Page 40 Component Location - 26 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations > Page 41 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Component ID: 161 Component : MODULE-SENTRY KEY REMOTE ENTRY/WCM Connector: Name : MODULE-SENTRY KEY REMOTE ENTRY/WCM Color : BLACK # of pins : 8 Pin Description Circuit 1 IGNITION SWITCH SENSE G20 20VT/BR 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4 GROUND Z937 20BK/YL 5 FUSED B(+) (I.O.D.) A411 20RD/LG 6 CAN B BUS (+) D55 20WT/OR 7 CAN B BUS (-) D54 20WT/PK 8-Component Location - 28 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 46 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 47 Keyless Entry Module: Diagrams Component ID: 161 Component : MODULE-SENTRY KEY REMOTE ENTRY/WCM Connector: Name : MODULE-SENTRY KEY REMOTE ENTRY/WCM Color : BLACK # of pins : 8 Pin Description Circuit 1 IGNITION SWITCH SENSE G20 20VT/BR 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4 GROUND Z937 20BK/YL 5 FUSED B(+) (I.O.D.) A411 20RD/LG 6 CAN B BUS (+) D55 20WT/OR 7 CAN B BUS (-) D54 20WT/PK 8-Component Location - 28 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 48 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Description and Operation > Description Keyless Entry Module: Description and Operation Description DESCRIPTION When a PCM and the SKREEM are replaced at the same time, perform the following steps in order: 1. Program the new PCM. 2. Program the new SKREEM. 3. Replace all ignition keys and program them to the new SKREEM. The Sentry Key REmote Entry Module (SKREEM) is sometimes referred to as the Wireless Control Module (WCM). The SKREEM/WCM is the primary component of the Sentry Key Immobilizer System (SKIS). It is also the receiver for the Remote Keyless Entry (RKE) system and the Tire Pressure Monitor (TPM) system. The SKREEM/WCM is located on the steering column, around the ignition lock cylinder housing and is concealed beneath the steering column shrouds. The molded black plastic housing for the SKREEM/WCM has an integral molded plastic halo-like antenna ring (3) that extends from one side. When the SKREEM/WCM is properly installed, the antenna ring is oriented around the ignition lock cylinder housing. A single connector (4) is located next to the antenna ring on the SKREEM/WCM housing (3). A molded plastic mounting tab (2) on the SKREEM/WCM housing secures the unit to the steering column. The SKREEM/WCM is connected to the vehicle electrical system through the instrument panel wire harness. The SKREEM/WCM cannot be adjusted or repaired. If faulty or damaged, the entire SKREEM unit must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Description and Operation > Description > Page 51 Keyless Entry Module: Description and Operation Operation OPERATION The Sentry Key REmote Entry Module (SKREEM), sometimes referred to as the Wireless Control Module (WCM), contains a Radio Frequency (RF) transceiver and a microprocessor. The SKREEM/WCM transmits RF signals to, and receives RF signals from the Sentry Key transponder through a tuned antenna enclosed within the molded plastic antenna ring integral to the SKREEM/WCM housing. If this antenna ring is not mounted properly around the ignition lock cylinder housing, communication problems between the SKREEM/WCM and the transponder may arise. These communication problems will result in Sentry Key transponder-related faults. The SKREEM also serves as the Remote Keyless Entry (RKE) RF receiver and, if the vehicle is so equipped, the receiver for the Tire Pressure Monitoring (TPM) system. The SKREEM/WCM communicates over the Controller Area Network (CAN) data bus with the Electromechanical Instrument Cluster (EMIC) (sometimes referred to as the Cab Compartment Node (CCN), the Powertrain Control Module (PCM), and/or the diagnostic scan tool. The SKREEM/WCM retains in memory the ID numbers of any Sentry Key transponder that is programmed into it. A maximum of eight Sentry Key transponders can be programmed into the SKREEM/WCM. For added system security, each SKREEM/WCM is programmed with a unique Secret Key code. This code is stored in memory, sent over the CAN data bus to the PCM, and is encoded to the transponder of every Sentry Key that is programmed into the SKREEM/WCM. Therefore, the Secret Key code is a common element that is found in every component of the Sentry Key Immobilizer System (SKIS). Another security code, called a PIN, is used to gain access to the SKREEM/WCM Secured Access Mode. The Secured Access Mode is required during service to perform the SKIS initialization and Sentry Key transponder programming procedures. The SKREEM/WCM also stores the Vehicle Identification Number (VIN) in its memory, which it learns through a CAN data bus message from the PCM during SKIS initialization. NOTE: After a SKREEM/WCM is replaced, the ignition/transponder keys need to be programmed to the new SKREEM/WCM. Follow the directions on the diagnostic scan tool. The transponder key for the SKREES/SKIM and the RKE will both be programmed during this operation. There is no need to program the fob of the key for RKE functionality once the transponder key is programmed to the new SKREEM/WCM. In the event that a SKREEM/WCM replacement is required, the Secret Key code can be transferred to the new SKREEM/WCM from the PCM using the diagnostic scan tool and the SKIS initialization procedure. Proper completion of the SKIS initialization will allow the existing Sentry Keys to be programmed into the new SKREEM/WCM so that new keys will not be required. In the event that the original Secret Key code cannot be recovered, SKREEM/WCM replacement will also require new Sentry Keys. The diagnostic scan tool will alert the technician during the SKIS initialization procedure if new Sentry Keys are required. When the ignition switch is turned to the On position, the SKREEM/WCM transmits an RF signal to the transponder in the ignition key. The SKREEM/WCM then waits for an RF signal response from the transponder. If the response received identifies the key as valid, the SKREEM/WCM sends a valid key message to the PCM over the CAN data bus. If the response received identifies the key as invalid or if no response is received from the key transponder, the SKREEM/WCM sends an invalid key message to the PCM. The PCM will enable or disable engine operation based upon the status of the SKREEM/WCM messages. It is important to note that the default condition in the PCM is an invalid key; therefore, if no message is received from the SKREEM/WCM by the PCM, the engine will be disabled and the vehicle immobilized after two seconds of running. The SKREEM/WCM also sends security indicator status messages to the EMIC/CCN over the CAN data bus to tell the EMIC/CCN how to operate the security indicator. The security indicator status message from the SKREEM/WCM tells the EMIC/CCN to turn the indicator on for about three seconds each time the ignition switch is turned to the On position as a bulb test. After completion of the bulb test, the SKREEM/WCM sends security indicator status messages to the EMIC/CCN to turn the indicator off, turn the indicator on, or to flash the indicator on and off. If the security indicator flashes or stays on solid after the bulb test, it signifies a SKIS fault. If the SKREEM/WCM detects a system malfunction and/or the SKIS has become inoperative, the security indicator will stay on solid. If the SKREEM/WCM detects an invalid key or if a key transponder-related fault exists, the security indicator will flash. If the vehicle is equipped with the Customer Learn transponder programming feature, the SKREEM/WCM will also send messages to the EMIC/CCN to flash the security indicator whenever the Customer Learn programming mode is being utilized. The SKIS performs a self-test each time the ignition switch is turned to the On position, and will store fault information in the form of a Diagnostic Trouble Code (DTC) in SKREEM/WCM memory if a system malfunction is detected. The SKREEM/WCM can be diagnosed, and any stored DTC can be retrieved using a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Description and Operation > Page 52 Keyless Entry Module: Testing and Inspection REMOTE KEYLESS ENTRY MODULE The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic information. Refer to the appropriate wiring information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Removal Keyless Entry Module: Service and Repair Removal REMOVAL NOTE: The steering wheel does not have to be removed to service the SKREEM/WCM. NOTE: The Steering Column Control Module (SCCM) assembly, which consists of the left/right multi-function switches and the clockspring, does not have to be removed to service the SKREEM/WCM. There is an access hole in the top of the right multi-function switch to access the mounting screw (2). 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. 2. Remove the upper and lower steering column shrouds. 3. Remove the SKREEM/WCM mounting screw (2) on the ignition lock assembly and separate the SKREEM/WCM (3) from the ignition lock assembly. 4. Disconnect the SKREEM/WCM electrical connector (4). 5. Remove SKREEM/WCM (1 and 3) from column (2). When a PCM and the SKREEM/WCM are replaced at the same time, perform the following steps in order. - Program the new PCM. - Program the new SKREEM/WCM. - Replace all ignition keys and program them to the new SKREEM/WCM. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Removal > Page 55 Keyless Entry Module: Service and Repair Installation INSTALLATION When a PCM and the SKREEM/WCM are replaced at the same time, perform the following steps in order. - Program the new PCM. - Program the new SKREEM/WCM. - Replace all ignition keys and program them to the new SKREEM/WCM. 1. Position the SKREEM/WCM (3) on the ignition lock housing and install the retaining screw (2). 2. Connect the SKREEM/WCM electrical connector (4). NOTE: On vehicles equipped with the optional Sentry Key Immobilizer System (SKIS), when the SKREEM is replaced with a new unit, a diagnostic scan tool MUST be used to initialize the new SKREEM and to program at least two Sentry Key transponders before the vehicle can be operated. 3. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations Seat Heater Control Module: Locations Component ID: 155 Component : MODULE-HEATED SEATS Connector: Name : MODULE-HEATED SEATS Color : BLACK # of pins : 10 A-B-C-D LEFT SEAT HEATER B(+) DRIVER P187 16LG/BR D RIGHT SEAT HEATER B(+) DRIVER P188 16LG/BR E FUSED IGNITION SWITCH OUTPUT (RUN) F937 14PK/YL F GROUND Z960 18BK G-- H-J LIN BUS D506 20WT/DG K RIGHT SEAT HEATER B(+) DRIVER P188 16LG/VT K LEFT SEAT HEATER B(+) DRIVER P187 16LG/VT Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Page 59 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Page 60 Seat Heater Control Module: Diagrams Component ID: 155 Component : MODULE-HEATED SEATS Connector: Name : MODULE-HEATED SEATS Color : BLACK # of pins : 10 A-B-C-D LEFT SEAT HEATER B(+) DRIVER P187 16LG/BR D RIGHT SEAT HEATER B(+) DRIVER P188 16LG/BR E FUSED IGNITION SWITCH OUTPUT (RUN) F937 14PK/YL F GROUND Z960 18BK G-- H-J LIN BUS D506 20WT/DG K RIGHT SEAT HEATER B(+) DRIVER P188 16LG/VT K LEFT SEAT HEATER B(+) DRIVER P187 16LG/VT Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Page 61 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation > Description Seat Heater Control Module: Description and Operation Description DESCRIPTION The heated seat module (2) is located under the left front seat. It has a single electrical connector (1) and a push pin style retainer that secures it to the seat pan. The module can be accessed from under the front left seat with the seat in the full back position. The heated seat module is a microprocessor designed to use the Local Interface Network (LIN) data bus messages from the instrument cluster also known as the Cabin Compartment Node (CCN). The CCN receives inputs from the heated seat switches and in turn signals the heated seat module to operate the heated seat elements for both front seats. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation > Description > Page 64 Seat Heater Control Module: Description and Operation Operation OPERATION The heated seat module operates on fused battery current received from the ignition switch. The module is grounded to the body at all times through the electrical connector. Inputs to the module include Local Interface Network (LIN) data bus messages and standard hardwired 12 volt power and ground. In response to the LIN inputs the heated seat module will control the battery current to the appropriate heated seat elements. When a heated seat switch LIN data bus signal is received by the heated seat module, the module energizes the selected heated seat element. The Low heat set point is about 38° C (100.4° F), and the High heat set point is about 42° C (107.6° F). In addition to operating the heated seat elements, the heated seat module sends LED illumination messages to the CCN via the LIN data bus. The CCN then sends the LED illumination message to the accessory switch bank so that the appropriate LEDs are illuminated for any given heating level. Pressing the switch once will select high-level heating. Pressing the switch a second time will select low-level heating. Pressing the switch a third time will shut the heating elements off. If the heated seat module detects a heated seat element OPEN or SHORT circuit, it will record and store the appropriate diagnostic trouble code (DTC). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation > Page 65 Seat Heater Control Module: Testing and Inspection HEATED SEAT MODULE In order to obtain conclusive testing, the heated seat system and the Local Interface Network (LIN) data bus circuit must be checked. Any diagnosis of the heated seat system should begin with the use of a scan tool. Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. NOTE: Vehicles equipped with the heated seat option utilize a low voltage cut-off feature. This feature turns off power to the heated seat system anytime vehicle voltage is below 11.7v or above 15.5v. Be certain to check the vehicle electrical system for proper voltage anytime the power seat system appears inoperative. Before any testing of the heated seat system is attempted, the battery should be fully-charged. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Removal Seat Heater Control Module: Service and Repair Removal REMOVAL CAUTION: The Heated Seat Module mounting tab can be damaged during module removal and installation. Use care to properly align tab to prevent binding that could result in tab breakage. 1. Position the right front seat to the full rearward position. 2. Disconnect and isolate the battery negative cable. 3. Disconnect the wire harness connector (4) from the heated seat module (3). 4. Unsnap the heated seat module retaining tab (2) from the seat pan (1). 5. Remove the heated seat module (3) from the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Removal > Page 68 Seat Heater Control Module: Service and Repair Installation INSTALLATION CAUTION: The Heated Seat Module mounting tab can be damaged during module removal and installation. Use care to properly align tab to prevent binding that could result in tab breakage. 1. Install the heated seat module (3) into the vehicle. 2. Position the retaining tab (2) with the mounting hole in the seat pan (1). Firmly apply even pressure to the module (3) until the mounting tab is fully seated. 3. Connect the wire harness connector (4) to the heated seat module (3). 4. Connect the battery negative cable. 5. Check for proper heated seat system operation. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > F50 > Feb > 07 > Recall - ABS Module Reprogramming Technical Service Bulletin # F50 Date: 070212 Recall - ABS Module Reprogramming February 2007 Dealer Service Instructions for: Safety Recall F50 Reprogram ABS Control Module Models 2007 (LX) Chrysler 300, Dodge Charger and Magnum - built from September 7, 2006 through November 18, 2006 (MDH 090701 - 111801). 2007 (JS) Chrysler Sebring - built from October 10, 2006 through November 15, 2006 (MDH 101019 - 111509). 2007 (PM) Dodge Caliber - built from September 7, 2006 through November 18, 2006 (MDH 090707 - 111801). 2007 (MK49) Jeep(R) Compass - built from September 7, 2006 through November 18, 2006 (MDH 090707 - 111801). 2007 (MK74) Jeep Patriot - built from September 7, 2006 through November 18, 2006 (MDH 090707 - 111801). 2007 (WK) Jeep Grand Cherokee - built from October 18, 2006 through December 6, 2006 (MDH 101813 - 120606). 2007 (XK) Jeep Commander - built from October 18, 2006 through December 6, 2006 (MDH 101813 - 120606). 2007 (KJ) Jeep Liberty - built from September 18, 2006 through November 30, 2006 (MDH 091807 - 113018). 2007 (KA) Dodge Nitro - built from September 18, 2006 through November 30, 2006 (MDH 091807 - 113018). 2007 (JK) Jeep Wrangler - built from November 9, 2006 through December 8, 2006 (MDH 110914 120811). NOTE: This recall applies only to the above vehicles equipped with an ESP/ABS system (sales code BNB, BRF, BRY, BR1 or BR3). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The software programmed into the Anti-Lock Brake System (ABS) control module on about 50,600 of the above vehicles may cause the rear brakes to lock up during certain braking conditions. This could result in a loss of vehicle control and cause a crash without warning. Repair The ABS control module must be reprogrammed (flashed). Parts Information No parts are required to perform this service procedure. Special Tools Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > F50 > Feb > 07 > Recall - ABS Module Reprogramming > Page 78 The existing special tools may be required to perform this repair. NOTE: The StarSCAN and the Star Mobile scan tools must be at version 7.03 or higher before this procedure can be performed. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is shown. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > F50 > Feb > 07 > Recall - ABS Module Reprogramming > Page 79 The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure NOTE: Reprogramming of the ABS Control Module can be performed using the StarSCAN scan tool or the StarMOBILE scan tool. A. Reprogram the ABS Control Module Using StarSCAN NOTE: The StarSCAN tool must be at version 7.03 or higher before this procedure can be performed. The software release level is visible in the blue header at the top of the StarSCAN screen. 1. Open the hood and install a battery charger. Verify that the charging rate provides approximately 13.5 volts. 2. Use the following procedure to determine the ABS Control Module software part number: a. Connect the StarSCAN to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. b. Power ON the StarSCAN. c. From the StarSCAN Home Screen, select "ECU View". d. From the StarSCAN ECU View Screen, select "ABS" from the list of modules. e. Select "More Options" and then select "ECU Flash". f. Record the part number displayed at the top of the "Flash ABS" screen for later reference. 3. Connect the CH9410 ethernet cable to the StarSCAN and the dealer's network drop. 4. Select "Browse for New File" and follow the on screen instructions. 5. Highlight the calibration and then select "Download to Scantool". 6. Select "Close" after the download is complete, disconnect the ethernet cable from the scan tool and then select "Back". 7. Highlight the listed calibration. 8. Select "Update Controller" and follow the screen instructions. 9. When the ABS control module update is complete, select "OK". 10. Verify the part number (resident flash file) at the top of the screen has updated to the new part number. 11. After completing the ABS control module reprogramming, clear all Diagnostic Trouble Codes (DTC's) using the following procedure: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > F50 > Feb > 07 > Recall - ABS Module Reprogramming > Page 80 a. Return to the "Main Menu" (Home Page). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's" and follow the screen prompts. 12. Disconnect and remove the StarSCAN and battery charger from the vehicle. B. Reprogram the ABS Control Module Using StarMOBILE NOTE: The StarMOBILE scan tool must be at version 7.03 or higher before this procedure can be performed. 1. Open the hood and install a battery charger. Verify that the charging rate provides approximately 13.5 volts. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. Connect the CH9410 ethernet cable to the StarMOBILE and the dealer's network drop. 5. From the desktop, launch the "StarMOBILE Desktop Client" software. 6. From the main menu on the StarMOBILE, select "System Status". 7. Establish a connection with the StarMOBILE scan tool. 8. Select "Flash Download". 9. Select "Next" and then enter your ID and password. 10. Enter the vehicle information (manually or use the automatic function). 11. Highlight the required flash file and select "Download to Client". 12. Select "BACK" then select "ECU View". 13. Select "ABS Antilock Brakes". 14. Select "More Options". 15. Select "ECU Flash". 16. Select "Manage Files". 17. Highlight downloaded flash file. 18. Select "Copy to SM Devise" and then follow the screen prompts. 19. Disconnect the ethernet cable from the StarMOBILE scan tool. 20. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 21. From the "System Status" screen press the "Exit" button. 22. From the "Main Menu" select "Enter Standalone Diagnostic Mode". 23. Select "ECU View" and press the select button. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > F50 > Feb > 07 > Recall - ABS Module Reprogramming > Page 81 24. Highlight "ABS" and press the select button. 25. Select "Flash ECU" and press the select button. 26. Verify the file number on the screen. If correct, press the select button and follow the screen prompts. 27. When the flash is complete, press the "OK" button. 28. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Return to the "Main Menu" (Home Page). b. From the "Home" screen, select "System View" and then select "All DTC's". c. Select the "Clear All Stored DTC's" and follow screen prompts. 29. Disconnect the StarMOBILE scan tool and battery charger from the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > F50 > Feb > 07 > Recall - ABS Module Reprogramming > Page 82 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > NHTSA06V493000 > Dec > 06 > Recall 06V493000: ABS Control Module Software Update Electronic Brake Control Module: Recalls Recall 06V493000: ABS Control Module Software Update MAKE/MODELS: MODEL/BUILD YEARS: Chrysler/300 2007 Chrysler/Sebring 2007 Dodge/Caliber 2007 Dodge/Charger 2007 Dodge/Magnum 2007 Dodge/Nitro 2007 Jeep/Commander 2007 Jeep/Compass 2007 Jeep/Grand Cherokee 2007 Jeep/Liberty 2007 Jeep/Wrangler 2007 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 06V493000 MFG'S REPORT DATE: December 22, 2006 COMPONENT: Service Brakes, Hydraulic: Antilock: Control Unit/Module POTENTIAL NUMBER OF UNITS AFFECTED: 62369 SUMMARY: On certain vehicles, the Antilock Brake System (ABS) control module software may cause the rear brakes to lock up during certain braking conditions. CONSEQUENCE: This could result in a loss of vehicle control and cause a crash without warning. REMEDY: Dealers will reprogram the ABS electronic control unit. The recall is expected to begin during February 2007. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. F50. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > F50 > Feb > 07 > Recall - ABS Module Reprogramming Technical Service Bulletin # F50 Date: 070212 Recall - ABS Module Reprogramming February 2007 Dealer Service Instructions for: Safety Recall F50 Reprogram ABS Control Module Models 2007 (LX) Chrysler 300, Dodge Charger and Magnum - built from September 7, 2006 through November 18, 2006 (MDH 090701 - 111801). 2007 (JS) Chrysler Sebring - built from October 10, 2006 through November 15, 2006 (MDH 101019 - 111509). 2007 (PM) Dodge Caliber - built from September 7, 2006 through November 18, 2006 (MDH 090707 - 111801). 2007 (MK49) Jeep(R) Compass - built from September 7, 2006 through November 18, 2006 (MDH 090707 - 111801). 2007 (MK74) Jeep Patriot - built from September 7, 2006 through November 18, 2006 (MDH 090707 - 111801). 2007 (WK) Jeep Grand Cherokee - built from October 18, 2006 through December 6, 2006 (MDH 101813 - 120606). 2007 (XK) Jeep Commander - built from October 18, 2006 through December 6, 2006 (MDH 101813 - 120606). 2007 (KJ) Jeep Liberty - built from September 18, 2006 through November 30, 2006 (MDH 091807 - 113018). 2007 (KA) Dodge Nitro - built from September 18, 2006 through November 30, 2006 (MDH 091807 - 113018). 2007 (JK) Jeep Wrangler - built from November 9, 2006 through December 8, 2006 (MDH 110914 120811). NOTE: This recall applies only to the above vehicles equipped with an ESP/ABS system (sales code BNB, BRF, BRY, BR1 or BR3). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The software programmed into the Anti-Lock Brake System (ABS) control module on about 50,600 of the above vehicles may cause the rear brakes to lock up during certain braking conditions. This could result in a loss of vehicle control and cause a crash without warning. Repair The ABS control module must be reprogrammed (flashed). Parts Information No parts are required to perform this service procedure. Special Tools Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > F50 > Feb > 07 > Recall - ABS Module Reprogramming > Page 92 The existing special tools may be required to perform this repair. NOTE: The StarSCAN and the Star Mobile scan tools must be at version 7.03 or higher before this procedure can be performed. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is shown. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > F50 > Feb > 07 > Recall - ABS Module Reprogramming > Page 93 The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure NOTE: Reprogramming of the ABS Control Module can be performed using the StarSCAN scan tool or the StarMOBILE scan tool. A. Reprogram the ABS Control Module Using StarSCAN NOTE: The StarSCAN tool must be at version 7.03 or higher before this procedure can be performed. The software release level is visible in the blue header at the top of the StarSCAN screen. 1. Open the hood and install a battery charger. Verify that the charging rate provides approximately 13.5 volts. 2. Use the following procedure to determine the ABS Control Module software part number: a. Connect the StarSCAN to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. b. Power ON the StarSCAN. c. From the StarSCAN Home Screen, select "ECU View". d. From the StarSCAN ECU View Screen, select "ABS" from the list of modules. e. Select "More Options" and then select "ECU Flash". f. Record the part number displayed at the top of the "Flash ABS" screen for later reference. 3. Connect the CH9410 ethernet cable to the StarSCAN and the dealer's network drop. 4. Select "Browse for New File" and follow the on screen instructions. 5. Highlight the calibration and then select "Download to Scantool". 6. Select "Close" after the download is complete, disconnect the ethernet cable from the scan tool and then select "Back". 7. Highlight the listed calibration. 8. Select "Update Controller" and follow the screen instructions. 9. When the ABS control module update is complete, select "OK". 10. Verify the part number (resident flash file) at the top of the screen has updated to the new part number. 11. After completing the ABS control module reprogramming, clear all Diagnostic Trouble Codes (DTC's) using the following procedure: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > F50 > Feb > 07 > Recall - ABS Module Reprogramming > Page 94 a. Return to the "Main Menu" (Home Page). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's" and follow the screen prompts. 12. Disconnect and remove the StarSCAN and battery charger from the vehicle. B. Reprogram the ABS Control Module Using StarMOBILE NOTE: The StarMOBILE scan tool must be at version 7.03 or higher before this procedure can be performed. 1. Open the hood and install a battery charger. Verify that the charging rate provides approximately 13.5 volts. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. Connect the CH9410 ethernet cable to the StarMOBILE and the dealer's network drop. 5. From the desktop, launch the "StarMOBILE Desktop Client" software. 6. From the main menu on the StarMOBILE, select "System Status". 7. Establish a connection with the StarMOBILE scan tool. 8. Select "Flash Download". 9. Select "Next" and then enter your ID and password. 10. Enter the vehicle information (manually or use the automatic function). 11. Highlight the required flash file and select "Download to Client". 12. Select "BACK" then select "ECU View". 13. Select "ABS Antilock Brakes". 14. Select "More Options". 15. Select "ECU Flash". 16. Select "Manage Files". 17. Highlight downloaded flash file. 18. Select "Copy to SM Devise" and then follow the screen prompts. 19. Disconnect the ethernet cable from the StarMOBILE scan tool. 20. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 21. From the "System Status" screen press the "Exit" button. 22. From the "Main Menu" select "Enter Standalone Diagnostic Mode". 23. Select "ECU View" and press the select button. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > F50 > Feb > 07 > Recall - ABS Module Reprogramming > Page 95 24. Highlight "ABS" and press the select button. 25. Select "Flash ECU" and press the select button. 26. Verify the file number on the screen. If correct, press the select button and follow the screen prompts. 27. When the flash is complete, press the "OK" button. 28. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Return to the "Main Menu" (Home Page). b. From the "Home" screen, select "System View" and then select "All DTC's". c. Select the "Clear All Stored DTC's" and follow screen prompts. 29. Disconnect the StarMOBILE scan tool and battery charger from the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > F50 > Feb > 07 > Recall - ABS Module Reprogramming > Page 96 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > NHTSA06V493000 > Dec > 06 > Recall 06V493000: ABS Control Module Software Update Electronic Brake Control Module: All Technical Service Bulletins Recall 06V493000: ABS Control Module Software Update MAKE/MODELS: MODEL/BUILD YEARS: Chrysler/300 2007 Chrysler/Sebring 2007 Dodge/Caliber 2007 Dodge/Charger 2007 Dodge/Magnum 2007 Dodge/Nitro 2007 Jeep/Commander 2007 Jeep/Compass 2007 Jeep/Grand Cherokee 2007 Jeep/Liberty 2007 Jeep/Wrangler 2007 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 06V493000 MFG'S REPORT DATE: December 22, 2006 COMPONENT: Service Brakes, Hydraulic: Antilock: Control Unit/Module POTENTIAL NUMBER OF UNITS AFFECTED: 62369 SUMMARY: On certain vehicles, the Antilock Brake System (ABS) control module software may cause the rear brakes to lock up during certain braking conditions. CONSEQUENCE: This could result in a loss of vehicle control and cause a crash without warning. REMEDY: Dealers will reprogram the ABS electronic control unit. The recall is expected to begin during February 2007. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. F50. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 101 Electronic Brake Control Module: Locations Component ID: 146 Component : MODULE-ANTI-LOCK BRAKES Connector: Name : MODULE-ANTI-LOCK BRAKES Color : BLACK # of pins : 47 Gender : FEMALE Pin Description Circuit 1 FUSED B(+) (PUMP) A921 12RD/DB 2-3-4-5-6-- 7-8 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 9-10 - 11 - 12 CAN C BUS (+) D65 20WT/BK 13 CAN C BUS (-) D64 20WT/LB 14 - 15 - 16 GROUND Z909 12BK/WT 17 - 18 DYNAMICS SENSOR HIGH DATA LINK D465 20WT/DB 19 DYNAMICS SENSOR LOW DATA LINK D464 20WT/YL 20 - 21 - 22 DYNAMICS SENSOR SUPPLY G4 18VT/LB 23 - 24 - 25 - 26 - 27 - 28 - 29 DYNAMICS SENSOR GROUND G94 18VT/DB 30 - 31 - 32 FUSED B(+) (VALVE) A922 14RD/BK 33 RIGHT FRONT WHEEL SPEED SENSOR SIGNAL B6 20WT/DB 34 RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY B7 20WT Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 102 35 - 36 LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY B4 20LG 37 LEFT REAR WHEEL SPEED SENSOR SIGNAL B3 20LG/DB 38 - 39 - 40 - 41 - 42 RIGHT REAR WHEEL SPEED SENSOR SIGNAL B1 20YL/DB 43 RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY B2 20YL 44 - 45 LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY B9 20DG/LG 46 LEFT FRONT WHEEL SPEED SENSOR SIGNAL B8 20DG/TN 47 GROUND Z909 12BK/WT Component Location - 5 Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 103 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 104 Electronic Brake Control Module: Diagrams Component ID: 146 Component : MODULE-ANTI-LOCK BRAKES Connector: Name : MODULE-ANTI-LOCK BRAKES Color : BLACK # of pins : 47 Gender : FEMALE Pin Description Circuit 1 FUSED B(+) (PUMP) A921 12RD/DB 2-3-4-5-6-- 7-8 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 9-10 - 11 - 12 CAN C BUS (+) D65 20WT/BK 13 CAN C BUS (-) D64 20WT/LB 14 - 15 - 16 GROUND Z909 12BK/WT 17 - 18 DYNAMICS SENSOR HIGH DATA LINK D465 20WT/DB 19 DYNAMICS SENSOR LOW DATA LINK D464 20WT/YL 20 - 21 - 22 DYNAMICS SENSOR SUPPLY G4 18VT/LB 23 - 24 - 25 - 26 - 27 - 28 - 29 DYNAMICS SENSOR GROUND G94 18VT/DB 30 - 31 - 32 FUSED B(+) (VALVE) A922 14RD/BK 33 RIGHT FRONT WHEEL SPEED SENSOR SIGNAL B6 20WT/DB 34 RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY B7 20WT Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 105 35 - 36 LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY B4 20LG 37 LEFT REAR WHEEL SPEED SENSOR SIGNAL B3 20LG/DB 38 - 39 - 40 - 41 - 42 RIGHT REAR WHEEL SPEED SENSOR SIGNAL B1 20YL/DB 43 RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY B2 20YL 44 - 45 LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY B9 20DG/LG 46 LEFT FRONT WHEEL SPEED SENSOR SIGNAL B8 20DG/TN 47 GROUND Z909 12BK/WT Component Location - 5 Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 106 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Description Electronic Brake Control Module: Description and Operation Description DESCRIPTION The Antilock Brake Module (ABM) is a microprocessor-based device which monitors the antilock brake system (ABS) during normal braking and controls it when the vehicle is in an ABS stop or when in a traction control or Electronic Stability Program (ESP) situation. The ABM utilizes a 47-way electrical connector on the vehicle wiring harness. The power source for the ABM is through the ignition switch in the RUN or ON position. The ABM (1) is mounted to the HCU (2) as part of the Integrated Control Unit (ICU). The ICU is located in the engine compartment on the inboard side of the right body frame rail behind the strut tower. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Description > Page 109 Electronic Brake Control Module: Description and Operation Operation OPERATION The primary functions of the Antilock Brake Module (ABM) are to: - Monitor the Antilock Brake System (ABS) and Electronic Stability Program (ESP) for proper operation. - Detect wheel locking or wheel slipping tendencies by monitoring the speed of all four wheels of the vehicle. - Control fluid modulation to the wheel brakes while the system is in ABS or traction control mode. - Modulates fluid pressure to the wheel brakes to control vehicle yaw rate in ESP mode. - Store diagnostic information. - Provide communication to the scan tool while in diagnostic mode. - Illuminate the amber ABS indicator in the instrument cluster. - Illuminate the yellow ESP/BAS indicator in the instrument cluster (if equipped). The ABM constantly monitors the ABS and ESP (if equipped) for proper operation. If the ABM detects a fault, it will turn on the amber ABS and yellow ESP/BAS indicators and disable the ABS or ESP if so equipped. The normal base braking system will remain operational at that time. The ABM continuously monitors the speed of each wheel through the signals generated by the wheel speed sensors to determine if any wheel is beginning to lock. When a wheel locking tendency is detected, the ABM commands the ABM solenoid coils to actuate. The coils then open and close the valves in the HCU that modulate brake fluid pressure in some or all of the hydraulic circuits. The ABM continues to control pressure in individual hydraulic circuits until a locking tendency is no longer present. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Removal Electronic Brake Control Module: Service and Repair Removal REMOVAL Due to packaging and limited space it is necessary to remove and disassemble the Integrated Control Unit (ICU) to service the Antilock Brake Module (ABM) on this vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Removal > Page 112 Electronic Brake Control Module: Service and Repair Installation INSTALLATION Due to packaging and limited space it is necessary to install the Antilock Brake Module (ABM) on the Hydraulic Control Unit (HCU), then install the Integrated Control Unit (ICU) on the vehicle as an assembly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Radiator Fan Relays are located in the Fuse/Relay block. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Relay-Radiator Fan-Low/High Radiator Cooling Fan Motor Relay: Diagrams Relay-Radiator Fan-Low/High Component ID: 183 Component : RELAY-RADIATOR FAN-LOW/HIGH Connector: Name : RELAY-RADIATOR FAN-LOW/HIGH Color : # of pins : 0 A1 FUSED B(+) A16 12RD/BR A2 LOW/HIGH RAD FAN RELAY OUTPUT N23 12DB/GY A3 - A4 FUSED B(+) A16 12RD/BR A5 LOW/HIGH RAD FAN RELAY CONTROL N201 20DB/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Relay-Radiator Fan-Low/High > Page 119 Radiator Cooling Fan Motor Relay: Diagrams Relay-Radiator Fan-Medium/High Component ID: 184 Component : RELAY-RADIATOR FAN-MEDIUM/HIGH Connector: Name : RELAY-RADIATOR FAN-MEDIUM/HIGH Color : # of pins : 0 C1 FUSED B(+) A16 12RD/BR C2 RAD FAN RELAY OUTPUT N24 12DG/DB C3 - C4 FUSED B(+) A16 12RD/BR C5 RAD FAN RELAY CONTROL N112 20DB/OR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Relay-Radiator Fan-Low/High > Page 120 Radiator Cooling Fan Motor Relay: Diagrams Relay-Radiator Fan-Series/Parallel Component ID: 185 Component : RELAY-RADIATOR FAN-SERIES/PARALLEL Connector: Name : RELAY-RADIATOR FAN-SERIES/PARALLEL Color : # of pins : 0 B1 FUSED B(+) A16 12RD/BR B2 GROUND Z901 16BK B3 RAD FAN RELAY OUTPUT N24 12DG/DB B4 SERIES/PARALLEL RAD FAN RELAY FEED N210 12DB/DG B5 RAD FAN RELAY CONTROL N112 20DB/OR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Description and Operation > Description Daytime Running Lamp Relay: Description and Operation Description DESCRIPTION Vehicles built for use in Canada, and also available as an option on vehicles for sale in the U.S., are equipped with a Daytime Running Lamp (DRL) system. All the exterior lighting messages come from Steering Control Module (SCM) or left multi-function switch on Local Interconnect Network (LIN) data bus and goes to the Cab Compartment Node (CCN), then the CCN sends out a Controller Area Network (CAN) data bus message to the Totally Integrated Power Module (TIPM) for each lighting function according to the request from left multi-function switch. Then the TIPM will turn ON/OFF the requested output. The DRL function is controlled by TIPM. Daytime running lamps are High beam lamps at lower intensity. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Description and Operation > Description > Page 126 Daytime Running Lamp Relay: Description and Operation Operation OPERATION The Canadian cluster provides steady illumination of the front turn signal when the ignition switch is in the ON position. The Daytime Running Lamp (DRL) function may be inhibited by activating the turn signals, the hazard flashers, the headlamp switch, or park brake. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Service and Repair > Removal Horn Relay: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove cover from Totally Integrated Power Module (TIPM). 3. Using special tool C-4817 (1), grip the relay (2) by the sides and pull upward with an even effort. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Service and Repair > Removal > Page 131 Horn Relay: Service and Repair Installation INSTALLATION 1. Align relay (2) with Totally Integrated Power Module (TIPM) and press into position. 2. Install cover to TIPM. 3. Connect battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Service and Repair > Removal Mini ISO Relay: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove cover from Totally Integrated Power module (TIPM). 3. Using special tool C-4817 (1), grip the relay (2) by the sides and pull upward with an even effort. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Service and Repair > Removal > Page 137 Mini ISO Relay: Service and Repair Installation INSTALLATION 1. Align relay (2) with Totally Integrated Power Module (TIPM) and press into position. 2. Install cover to TIPM. 3. Connect battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Recalls: > G42 > Jan > 08 > Campaign TIPM Software Update for Antitheft System Technical Service Bulletin # G42 Date: 080101 Campaign - TIPM Software Update for Antitheft System January 2008 Distributor/Dealer Service Instructions for: Customer Satisfaction Notice G42 TIPM Re-Configure, Anti-Theft System Models 2007 2008 (JS/PM/MK) Sebring, Avenger, Caliber, Compass and Patriot vehicles (International Markets Only) NOTE: This customer satisfaction notice applies only to the above vehicles built at the Sterling Heights Assembly Plant through July 25, 2007 (MDH 0725XX) and the Belvidere Assembly Plant through July 23, 2007 (MDH 0723XX). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this customer satisfaction notice. IMPORTANT: Some of the involved vehicles may be in distributor/dealer used vehicle inventory. Distributors/Dealers should complete this recall service on these vehicles before retail delivery. Distributors/Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Totally Integrated Power Module (TIPM) vehicles may be configured incorrectly preventing the Anti-Theft Security System from operating properly. Repair The Totally Integrated Power Module (TIPM) must be Re-Configured. Special Tools These existing special tools are required to perform this repair. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Recalls: > G42 > Jan > 08 > Campaign TIPM Software Update for Antitheft System > Page 146 Use the labor operation number and time allowance shown. Distributor/ Dealer Notification and Vehicle List Regional offices will receive an electronic list of involved vehicles. The Vehicle List is arranged by Distributor/Dealer code and in Vehicle Identification Number (VIN) sequence. The lists are for Distributor/Dealer reference in arranging for service of involved vehicles. Owner Notification and Service Scheduling All involved vehicle owners should be notified of the service requirement by their Distributor/Dealer. Owners are requested to schedule appointments for this service. A sample copy of the owner notification letter is included. Vehicle Lists, Global Recall System, VIP and Distributor/Dealer Follow up All involved vehicles have been entered into the Global Recall System (GRS) and Vehicle Information Plus (VIP) for Distributor/Dealer inquiry as needed. GRS provides involved Distributors/Dealers with an updated VIN list of their incomplete vehicles. Completed vehicles are removed from GRS within several days of repair claim submission. Distributors/Dealers must perform this repair on all unsold vehicles before retail delivery. Distributors/Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Additional Information If you have any questions or need assistance in completing this action, please contact your International Service and Parts Manager. Global Service & Parts - International Chrysler LLC Service Procedure NOTE: Use StarSCAN(R) to perform this Customer Satisfaction Notice. This procedure must be performed using software release 8.02 or higher. Re-Configure the TIPM using StarSCAN(R) 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN(R) Ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN® vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN(R). 5. Re-Configure the TIPM as Follows: a. With the StarSCAN(R) on the "Home" screen, select "ECU View". b. Select "TIPMCGW Central Gateway" in the list of modules. c. Select "Misc Functions". Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Recalls: > G42 > Jan > 08 > Campaign TIPM Software Update for Antitheft System > Page 147 d. Select "Restore Vehicle Configuration". e. Press "Start". f. Follow the prompts listed on the StarSCAN(R). g. When prompted, Enter the full 17 digit VIN found on the VIN plate. NOTE: Assure the correct VIN is input into the StarSCAN(R). h. Select "Next". NOTE: The StarSCAN(R) must be connected to the dealer network drop. i. Follow the prompts listed on the StarSCAN(R). 6. Check and clear any Diagnostic Trouble Codes (DTC's) that may have been set. 7. Turn the ignition key to the "OFF" position and remove the StarSCAN(R) unit, StarSCAN(R) cable, and battery charger from the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition Power Distribution Module: Customer Interest Antitheft System - Engine No Crank/No Start Condition NUMBER: 08-007-08 REV. A GROUP: Electrical DATE: July 04,2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-007-08, DATED MARCH 04, 2008. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. DO NOT ORDER PART NUMBER 05026070AP UNTIL JULY 21, 2008. ALL OTHER PART NUMBERS ARE AVAILABLE NOW. SUBJECT: No Engine Crank Or No Engine Start Due To Electronic Lockup Of The WCM / SKREEM OVERVIEW: This bulletin involves the replacement of the Wireless Control Module (WCM), and if equipped, the replacement of the Electric Steering Column Lock (ELV). The WCM is also referred to as the Sentry Key Remote Entry Module (SKREEM). MODELS: 2007 - 2008 (DR/DH/D1/DC/DM) Ram Truck (1500/2500/3500/4500/5500) 2007 - 2008 (JK) Wrangler 2007 - 2008 (J1) Sebring (China) 2007 - 2008 (JS) Avenger/Sebring 2007 - 2008 (KA) Nitro 2008 (KK) Liberty/Cherokee 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber 2006 - 2008 (PT) Chrysler PT Cruiser NOTE: This bulletin applies to vehicles built on or before May 05, 2008 (MDH 0505XX). SYMPTOM/CONDITION: The customer will experience a no engine crank AND a no engine start condition. Also, the remote keyless entry (RKE) system will not operate. This condition may be due to an electrostatic discharge (ESD) from the ignition key into the Wireless Control Module (WCM), causing the WCM to electronically lockup. This condition may occur more frequently in dry and/or cold weather conditions where a sufficient electrostatic charge is more easily produced. This condition is corrected by the replacement of the WCM. DIAGNOSIS: 1. With the condition present (i.e. the vehicle in the no crank / no start condition), connect the StarSCAN(R) scan tool to the vehicle. 2. Turn the ignition switch to the "ON position, and power up the StarSCAN(R). 3. If the WCM is electronically locked up, the StarSCAN(R) will display the WCM as being "off bus". 4. If the no crank / no start condition is present, and the WCM is "off bus", then reset the WCM by temporarily removing the IOD fuse (with the key out of the ignition switch), wait for 10 seconds and then reinstall the IOD fuse. 5. With the IOD fuse reset having been performed, verify that the vehicle will now crank, start, and run. 6. If the condition is temporarily corrected by performing the above steps, and if the part number of the WCM is earlier than the part number of the WCM listed in the part reference table in the Service Bulletin Parts Required Section below, then perform the Repair Procedure. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 153 PARTS REQUIRED: NOTE: The part numbers listed in the following part reference table are to be used as A GUIDE to help determine if the WCM, that is currently in the vehicle, may require replacement. If it is determined that the WCM requires replacement, then ALWAYS REFER TO THE PARTS MANUAL to determine the correct WCM for the specific vehicle in question. In some earlier model years, the WCM may rule (supersede) to one of the part numbers listed in the table. ALWAYS REFER TO THE PARTS MANUAL (not the part reference table) to determine the correct part number ruling (supercedence / substitution). MAKE CERTAIN THAT THE CORRECT WCM IS ORDERED THE FIRST TIME FOR THE SPECIFIC VEHICLE IN QUESTION. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 154 REPAIR PROCEDURE: NOTE: If the vehicle (a JS model vehicle in certain International markets) is equipped with an Electric Steering Column Lock (ELV), then the WCM and the ELV must be replaced. Replace the WCM and then the ELV. Next program the WCM and at least one (1) ignition key BEFORE programming the ELV. IMPORTANT: Not following this repair process correctly will cause the new ELV to fail. NOTE: Insert the ignition key into the ignition lock cylinder. This will move the shaft lock module locking bolt to the unlocked position. LEAVE the key in the lock cylinder while the shaft lock module is being removed. 1. If vehicle is equipped with a Steering Shaft Lock Module (JS - Avenger I Stratus - some International Markets), then the Shaft Lock Module will require replacement. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Security Information > Module, Shaft Lock > Removal and Installation. NOTE: The shaft lock module cannot be removed from the steering column while the locking bolt is in the locked position without irreversibly damaging the column. Before attempting service, the ignition key must have been inserted into the ignition lock cylinder. Then rotate the steering wheel from side to side. If the steering wheel can be rotated, the locking bolt is in the unlocked position. Leave the key in the ignition lock cylinder until shaft lock module removal has been completed. If the steering wheel cannot be rotated, test and repair the wiring circuits between the module and the ignition switch as required. If no problem is found in these circuits, the module has failed with the locking bolt in the locked position and both the module and the steering column must be replaced with new units. 2. Replace the WCM/SKREEM. Refer to TechCONNECT for detailed service information. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Service Information > Module, Sentry Key Remote Entry > Removal and Installation. NOTE: Obtain the vehicle PIN number prior to programming WCM/SKREEM or ELV. NOTE: If during the following steps the PIN number is properly entered but is rejected, then reenter the PIN number again until it is accepted. 3. After both the WCM/SKREEM and the ELV (if equipped) have been replaced, Program the WCM/SKREEM as follows: a. Turn the ignition key to the ON position, (Engine Off) b. Connect the scan tool (StarSCAN(R)) to the data link connector and turn the ignition to the RUN position, (engine off). c. Select "ECU View." d. Scroll down and select "WCM" in the list of modules. e. Select "Misc. Functions." f. Scroll to "WCM Replaced." g. Press "Start". h. Press "Next". i. Select "Show Keyboard". j. Enter the vehicle PIN number. k. Select "Next". l. Verify PIN is correct. m. Select "Next". n. Follow on-screen prompts to complete WCM function programing for Tire Pressure Monitoring (TPM) and so on. 0. Turn the ignition key to the OFF position. Wait 30 seconds. p. Turn the ignition key to the ON position, (Engine Off) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 155 q. Select "ECU View". r. Scroll down and select "WCM" in the list of modules. s. Select "Misc. Functions." t. Select "Program Ign. Keys" and follow on-screen prompts. u. Select "Complete". v. Verify ignition key will start vehicle and the Remote Keyless Entry (RKE) functions operate. CAUTION: If the vehicle is equipped with a Shaft Lock Module (used in some International Markets on JS model vehicles), then at least one (1 ignition key must have been programmed to the new WCM BEFORE the new Shaft Lock Module is "married" to the new WCM. 4. Is the vehicle equipped with Steering Shaft Lock Module (ELV)? a. Yes >> Proceed to Step # 5. b. No >>Repair is complete. 5. Program the ELV as follows; a. Select "ECU View". b. Scroll down and select "WCM" in the list of modules. c. Select "Misc. Functions". d. Scroll to "ELV Replaced." e. Press "Start". f. When complete, verify steering shaft lock mechanism is operating. Remove and insert key from the ignition lock cylinder and listen for solenoid "click at lower end of column. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 156 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition Power Distribution Module: All Technical Service Bulletins Antitheft System - Engine No Crank/No Start Condition NUMBER: 08-007-08 REV. A GROUP: Electrical DATE: July 04,2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-007-08, DATED MARCH 04, 2008. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. DO NOT ORDER PART NUMBER 05026070AP UNTIL JULY 21, 2008. ALL OTHER PART NUMBERS ARE AVAILABLE NOW. SUBJECT: No Engine Crank Or No Engine Start Due To Electronic Lockup Of The WCM / SKREEM OVERVIEW: This bulletin involves the replacement of the Wireless Control Module (WCM), and if equipped, the replacement of the Electric Steering Column Lock (ELV). The WCM is also referred to as the Sentry Key Remote Entry Module (SKREEM). MODELS: 2007 - 2008 (DR/DH/D1/DC/DM) Ram Truck (1500/2500/3500/4500/5500) 2007 - 2008 (JK) Wrangler 2007 - 2008 (J1) Sebring (China) 2007 - 2008 (JS) Avenger/Sebring 2007 - 2008 (KA) Nitro 2008 (KK) Liberty/Cherokee 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber 2006 - 2008 (PT) Chrysler PT Cruiser NOTE: This bulletin applies to vehicles built on or before May 05, 2008 (MDH 0505XX). SYMPTOM/CONDITION: The customer will experience a no engine crank AND a no engine start condition. Also, the remote keyless entry (RKE) system will not operate. This condition may be due to an electrostatic discharge (ESD) from the ignition key into the Wireless Control Module (WCM), causing the WCM to electronically lockup. This condition may occur more frequently in dry and/or cold weather conditions where a sufficient electrostatic charge is more easily produced. This condition is corrected by the replacement of the WCM. DIAGNOSIS: 1. With the condition present (i.e. the vehicle in the no crank / no start condition), connect the StarSCAN(R) scan tool to the vehicle. 2. Turn the ignition switch to the "ON position, and power up the StarSCAN(R). 3. If the WCM is electronically locked up, the StarSCAN(R) will display the WCM as being "off bus". 4. If the no crank / no start condition is present, and the WCM is "off bus", then reset the WCM by temporarily removing the IOD fuse (with the key out of the ignition switch), wait for 10 seconds and then reinstall the IOD fuse. 5. With the IOD fuse reset having been performed, verify that the vehicle will now crank, start, and run. 6. If the condition is temporarily corrected by performing the above steps, and if the part number of the WCM is earlier than the part number of the WCM listed in the part reference table in the Service Bulletin Parts Required Section below, then perform the Repair Procedure. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 162 PARTS REQUIRED: NOTE: The part numbers listed in the following part reference table are to be used as A GUIDE to help determine if the WCM, that is currently in the vehicle, may require replacement. If it is determined that the WCM requires replacement, then ALWAYS REFER TO THE PARTS MANUAL to determine the correct WCM for the specific vehicle in question. In some earlier model years, the WCM may rule (supersede) to one of the part numbers listed in the table. ALWAYS REFER TO THE PARTS MANUAL (not the part reference table) to determine the correct part number ruling (supercedence / substitution). MAKE CERTAIN THAT THE CORRECT WCM IS ORDERED THE FIRST TIME FOR THE SPECIFIC VEHICLE IN QUESTION. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 163 REPAIR PROCEDURE: NOTE: If the vehicle (a JS model vehicle in certain International markets) is equipped with an Electric Steering Column Lock (ELV), then the WCM and the ELV must be replaced. Replace the WCM and then the ELV. Next program the WCM and at least one (1) ignition key BEFORE programming the ELV. IMPORTANT: Not following this repair process correctly will cause the new ELV to fail. NOTE: Insert the ignition key into the ignition lock cylinder. This will move the shaft lock module locking bolt to the unlocked position. LEAVE the key in the lock cylinder while the shaft lock module is being removed. 1. If vehicle is equipped with a Steering Shaft Lock Module (JS - Avenger I Stratus - some International Markets), then the Shaft Lock Module will require replacement. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Security Information > Module, Shaft Lock > Removal and Installation. NOTE: The shaft lock module cannot be removed from the steering column while the locking bolt is in the locked position without irreversibly damaging the column. Before attempting service, the ignition key must have been inserted into the ignition lock cylinder. Then rotate the steering wheel from side to side. If the steering wheel can be rotated, the locking bolt is in the unlocked position. Leave the key in the ignition lock cylinder until shaft lock module removal has been completed. If the steering wheel cannot be rotated, test and repair the wiring circuits between the module and the ignition switch as required. If no problem is found in these circuits, the module has failed with the locking bolt in the locked position and both the module and the steering column must be replaced with new units. 2. Replace the WCM/SKREEM. Refer to TechCONNECT for detailed service information. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Service Information > Module, Sentry Key Remote Entry > Removal and Installation. NOTE: Obtain the vehicle PIN number prior to programming WCM/SKREEM or ELV. NOTE: If during the following steps the PIN number is properly entered but is rejected, then reenter the PIN number again until it is accepted. 3. After both the WCM/SKREEM and the ELV (if equipped) have been replaced, Program the WCM/SKREEM as follows: a. Turn the ignition key to the ON position, (Engine Off) b. Connect the scan tool (StarSCAN(R)) to the data link connector and turn the ignition to the RUN position, (engine off). c. Select "ECU View." d. Scroll down and select "WCM" in the list of modules. e. Select "Misc. Functions." f. Scroll to "WCM Replaced." g. Press "Start". h. Press "Next". i. Select "Show Keyboard". j. Enter the vehicle PIN number. k. Select "Next". l. Verify PIN is correct. m. Select "Next". n. Follow on-screen prompts to complete WCM function programing for Tire Pressure Monitoring (TPM) and so on. 0. Turn the ignition key to the OFF position. Wait 30 seconds. p. Turn the ignition key to the ON position, (Engine Off) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 164 q. Select "ECU View". r. Scroll down and select "WCM" in the list of modules. s. Select "Misc. Functions." t. Select "Program Ign. Keys" and follow on-screen prompts. u. Select "Complete". v. Verify ignition key will start vehicle and the Remote Keyless Entry (RKE) functions operate. CAUTION: If the vehicle is equipped with a Shaft Lock Module (used in some International Markets on JS model vehicles), then at least one (1 ignition key must have been programmed to the new WCM BEFORE the new Shaft Lock Module is "married" to the new WCM. 4. Is the vehicle equipped with Steering Shaft Lock Module (ELV)? a. Yes >> Proceed to Step # 5. b. No >>Repair is complete. 5. Program the ELV as follows; a. Select "ECU View". b. Scroll down and select "WCM" in the list of modules. c. Select "Misc. Functions". d. Scroll to "ELV Replaced." e. Press "Start". f. When complete, verify steering shaft lock mechanism is operating. Remove and insert key from the ignition lock cylinder and listen for solenoid "click at lower end of column. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 165 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > G42 > Jan > 08 > Campaign - TIPM Software Update for Antitheft System Technical Service Bulletin # G42 Date: 080101 Campaign - TIPM Software Update for Antitheft System January 2008 Distributor/Dealer Service Instructions for: Customer Satisfaction Notice G42 TIPM Re-Configure, Anti-Theft System Models 2007 2008 (JS/PM/MK) Sebring, Avenger, Caliber, Compass and Patriot vehicles (International Markets Only) NOTE: This customer satisfaction notice applies only to the above vehicles built at the Sterling Heights Assembly Plant through July 25, 2007 (MDH 0725XX) and the Belvidere Assembly Plant through July 23, 2007 (MDH 0723XX). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this customer satisfaction notice. IMPORTANT: Some of the involved vehicles may be in distributor/dealer used vehicle inventory. Distributors/Dealers should complete this recall service on these vehicles before retail delivery. Distributors/Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Totally Integrated Power Module (TIPM) vehicles may be configured incorrectly preventing the Anti-Theft Security System from operating properly. Repair The Totally Integrated Power Module (TIPM) must be Re-Configured. Special Tools These existing special tools are required to perform this repair. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > G42 > Jan > 08 > Campaign - TIPM Software Update for Antitheft System > Page 170 Use the labor operation number and time allowance shown. Distributor/ Dealer Notification and Vehicle List Regional offices will receive an electronic list of involved vehicles. The Vehicle List is arranged by Distributor/Dealer code and in Vehicle Identification Number (VIN) sequence. The lists are for Distributor/Dealer reference in arranging for service of involved vehicles. Owner Notification and Service Scheduling All involved vehicle owners should be notified of the service requirement by their Distributor/Dealer. Owners are requested to schedule appointments for this service. A sample copy of the owner notification letter is included. Vehicle Lists, Global Recall System, VIP and Distributor/Dealer Follow up All involved vehicles have been entered into the Global Recall System (GRS) and Vehicle Information Plus (VIP) for Distributor/Dealer inquiry as needed. GRS provides involved Distributors/Dealers with an updated VIN list of their incomplete vehicles. Completed vehicles are removed from GRS within several days of repair claim submission. Distributors/Dealers must perform this repair on all unsold vehicles before retail delivery. Distributors/Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Additional Information If you have any questions or need assistance in completing this action, please contact your International Service and Parts Manager. Global Service & Parts - International Chrysler LLC Service Procedure NOTE: Use StarSCAN(R) to perform this Customer Satisfaction Notice. This procedure must be performed using software release 8.02 or higher. Re-Configure the TIPM using StarSCAN(R) 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN(R) Ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN® vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN(R). 5. Re-Configure the TIPM as Follows: a. With the StarSCAN(R) on the "Home" screen, select "ECU View". b. Select "TIPMCGW Central Gateway" in the list of modules. c. Select "Misc Functions". Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > G42 > Jan > 08 > Campaign - TIPM Software Update for Antitheft System > Page 171 d. Select "Restore Vehicle Configuration". e. Press "Start". f. Follow the prompts listed on the StarSCAN(R). g. When prompted, Enter the full 17 digit VIN found on the VIN plate. NOTE: Assure the correct VIN is input into the StarSCAN(R). h. Select "Next". NOTE: The StarSCAN(R) must be connected to the dealer network drop. i. Follow the prompts listed on the StarSCAN(R). 6. Check and clear any Diagnostic Trouble Codes (DTC's) that may have been set. 7. Turn the ignition key to the "OFF" position and remove the StarSCAN(R) unit, StarSCAN(R) cable, and battery charger from the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition Power Distribution Module: All Technical Service Bulletins Antitheft System - Engine No Crank/No Start Condition NUMBER: 08-007-08 REV. A GROUP: Electrical DATE: July 04,2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-007-08, DATED MARCH 04, 2008. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. DO NOT ORDER PART NUMBER 05026070AP UNTIL JULY 21, 2008. ALL OTHER PART NUMBERS ARE AVAILABLE NOW. SUBJECT: No Engine Crank Or No Engine Start Due To Electronic Lockup Of The WCM / SKREEM OVERVIEW: This bulletin involves the replacement of the Wireless Control Module (WCM), and if equipped, the replacement of the Electric Steering Column Lock (ELV). The WCM is also referred to as the Sentry Key Remote Entry Module (SKREEM). MODELS: 2007 - 2008 (DR/DH/D1/DC/DM) Ram Truck (1500/2500/3500/4500/5500) 2007 - 2008 (JK) Wrangler 2007 - 2008 (J1) Sebring (China) 2007 - 2008 (JS) Avenger/Sebring 2007 - 2008 (KA) Nitro 2008 (KK) Liberty/Cherokee 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber 2006 - 2008 (PT) Chrysler PT Cruiser NOTE: This bulletin applies to vehicles built on or before May 05, 2008 (MDH 0505XX). SYMPTOM/CONDITION: The customer will experience a no engine crank AND a no engine start condition. Also, the remote keyless entry (RKE) system will not operate. This condition may be due to an electrostatic discharge (ESD) from the ignition key into the Wireless Control Module (WCM), causing the WCM to electronically lockup. This condition may occur more frequently in dry and/or cold weather conditions where a sufficient electrostatic charge is more easily produced. This condition is corrected by the replacement of the WCM. DIAGNOSIS: 1. With the condition present (i.e. the vehicle in the no crank / no start condition), connect the StarSCAN(R) scan tool to the vehicle. 2. Turn the ignition switch to the "ON position, and power up the StarSCAN(R). 3. If the WCM is electronically locked up, the StarSCAN(R) will display the WCM as being "off bus". 4. If the no crank / no start condition is present, and the WCM is "off bus", then reset the WCM by temporarily removing the IOD fuse (with the key out of the ignition switch), wait for 10 seconds and then reinstall the IOD fuse. 5. With the IOD fuse reset having been performed, verify that the vehicle will now crank, start, and run. 6. If the condition is temporarily corrected by performing the above steps, and if the part number of the WCM is earlier than the part number of the WCM listed in the part reference table in the Service Bulletin Parts Required Section below, then perform the Repair Procedure. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 177 PARTS REQUIRED: NOTE: The part numbers listed in the following part reference table are to be used as A GUIDE to help determine if the WCM, that is currently in the vehicle, may require replacement. If it is determined that the WCM requires replacement, then ALWAYS REFER TO THE PARTS MANUAL to determine the correct WCM for the specific vehicle in question. In some earlier model years, the WCM may rule (supersede) to one of the part numbers listed in the table. ALWAYS REFER TO THE PARTS MANUAL (not the part reference table) to determine the correct part number ruling (supercedence / substitution). MAKE CERTAIN THAT THE CORRECT WCM IS ORDERED THE FIRST TIME FOR THE SPECIFIC VEHICLE IN QUESTION. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 178 REPAIR PROCEDURE: NOTE: If the vehicle (a JS model vehicle in certain International markets) is equipped with an Electric Steering Column Lock (ELV), then the WCM and the ELV must be replaced. Replace the WCM and then the ELV. Next program the WCM and at least one (1) ignition key BEFORE programming the ELV. IMPORTANT: Not following this repair process correctly will cause the new ELV to fail. NOTE: Insert the ignition key into the ignition lock cylinder. This will move the shaft lock module locking bolt to the unlocked position. LEAVE the key in the lock cylinder while the shaft lock module is being removed. 1. If vehicle is equipped with a Steering Shaft Lock Module (JS - Avenger I Stratus - some International Markets), then the Shaft Lock Module will require replacement. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Security Information > Module, Shaft Lock > Removal and Installation. NOTE: The shaft lock module cannot be removed from the steering column while the locking bolt is in the locked position without irreversibly damaging the column. Before attempting service, the ignition key must have been inserted into the ignition lock cylinder. Then rotate the steering wheel from side to side. If the steering wheel can be rotated, the locking bolt is in the unlocked position. Leave the key in the ignition lock cylinder until shaft lock module removal has been completed. If the steering wheel cannot be rotated, test and repair the wiring circuits between the module and the ignition switch as required. If no problem is found in these circuits, the module has failed with the locking bolt in the locked position and both the module and the steering column must be replaced with new units. 2. Replace the WCM/SKREEM. Refer to TechCONNECT for detailed service information. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Service Information > Module, Sentry Key Remote Entry > Removal and Installation. NOTE: Obtain the vehicle PIN number prior to programming WCM/SKREEM or ELV. NOTE: If during the following steps the PIN number is properly entered but is rejected, then reenter the PIN number again until it is accepted. 3. After both the WCM/SKREEM and the ELV (if equipped) have been replaced, Program the WCM/SKREEM as follows: a. Turn the ignition key to the ON position, (Engine Off) b. Connect the scan tool (StarSCAN(R)) to the data link connector and turn the ignition to the RUN position, (engine off). c. Select "ECU View." d. Scroll down and select "WCM" in the list of modules. e. Select "Misc. Functions." f. Scroll to "WCM Replaced." g. Press "Start". h. Press "Next". i. Select "Show Keyboard". j. Enter the vehicle PIN number. k. Select "Next". l. Verify PIN is correct. m. Select "Next". n. Follow on-screen prompts to complete WCM function programing for Tire Pressure Monitoring (TPM) and so on. 0. Turn the ignition key to the OFF position. Wait 30 seconds. p. Turn the ignition key to the ON position, (Engine Off) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 179 q. Select "ECU View". r. Scroll down and select "WCM" in the list of modules. s. Select "Misc. Functions." t. Select "Program Ign. Keys" and follow on-screen prompts. u. Select "Complete". v. Verify ignition key will start vehicle and the Remote Keyless Entry (RKE) functions operate. CAUTION: If the vehicle is equipped with a Shaft Lock Module (used in some International Markets on JS model vehicles), then at least one (1 ignition key must have been programmed to the new WCM BEFORE the new Shaft Lock Module is "married" to the new WCM. 4. Is the vehicle equipped with Steering Shaft Lock Module (ELV)? a. Yes >> Proceed to Step # 5. b. No >>Repair is complete. 5. Program the ELV as follows; a. Select "ECU View". b. Scroll down and select "WCM" in the list of modules. c. Select "Misc. Functions". d. Scroll to "ELV Replaced." e. Press "Start". f. When complete, verify steering shaft lock mechanism is operating. Remove and insert key from the ignition lock cylinder and listen for solenoid "click at lower end of column. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 180 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Distribution Module: > G42 > Jan > 08 > Campaign - TIPM Software Update for Antitheft System Technical Service Bulletin # G42 Date: 080101 Campaign - TIPM Software Update for Antitheft System January 2008 Distributor/Dealer Service Instructions for: Customer Satisfaction Notice G42 TIPM Re-Configure, Anti-Theft System Models 2007 2008 (JS/PM/MK) Sebring, Avenger, Caliber, Compass and Patriot vehicles (International Markets Only) NOTE: This customer satisfaction notice applies only to the above vehicles built at the Sterling Heights Assembly Plant through July 25, 2007 (MDH 0725XX) and the Belvidere Assembly Plant through July 23, 2007 (MDH 0723XX). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this customer satisfaction notice. IMPORTANT: Some of the involved vehicles may be in distributor/dealer used vehicle inventory. Distributors/Dealers should complete this recall service on these vehicles before retail delivery. Distributors/Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Totally Integrated Power Module (TIPM) vehicles may be configured incorrectly preventing the Anti-Theft Security System from operating properly. Repair The Totally Integrated Power Module (TIPM) must be Re-Configured. Special Tools These existing special tools are required to perform this repair. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Distribution Module: > G42 > Jan > 08 > Campaign - TIPM Software Update for Antitheft System > Page 186 Use the labor operation number and time allowance shown. Distributor/ Dealer Notification and Vehicle List Regional offices will receive an electronic list of involved vehicles. The Vehicle List is arranged by Distributor/Dealer code and in Vehicle Identification Number (VIN) sequence. The lists are for Distributor/Dealer reference in arranging for service of involved vehicles. Owner Notification and Service Scheduling All involved vehicle owners should be notified of the service requirement by their Distributor/Dealer. Owners are requested to schedule appointments for this service. A sample copy of the owner notification letter is included. Vehicle Lists, Global Recall System, VIP and Distributor/Dealer Follow up All involved vehicles have been entered into the Global Recall System (GRS) and Vehicle Information Plus (VIP) for Distributor/Dealer inquiry as needed. GRS provides involved Distributors/Dealers with an updated VIN list of their incomplete vehicles. Completed vehicles are removed from GRS within several days of repair claim submission. Distributors/Dealers must perform this repair on all unsold vehicles before retail delivery. Distributors/Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Additional Information If you have any questions or need assistance in completing this action, please contact your International Service and Parts Manager. Global Service & Parts - International Chrysler LLC Service Procedure NOTE: Use StarSCAN(R) to perform this Customer Satisfaction Notice. This procedure must be performed using software release 8.02 or higher. Re-Configure the TIPM using StarSCAN(R) 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN(R) Ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN® vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN(R). 5. Re-Configure the TIPM as Follows: a. With the StarSCAN(R) on the "Home" screen, select "ECU View". b. Select "TIPMCGW Central Gateway" in the list of modules. c. Select "Misc Functions". Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Distribution Module: > G42 > Jan > 08 > Campaign - TIPM Software Update for Antitheft System > Page 187 d. Select "Restore Vehicle Configuration". e. Press "Start". f. Follow the prompts listed on the StarSCAN(R). g. When prompted, Enter the full 17 digit VIN found on the VIN plate. NOTE: Assure the correct VIN is input into the StarSCAN(R). h. Select "Next". NOTE: The StarSCAN(R) must be connected to the dealer network drop. i. Follow the prompts listed on the StarSCAN(R). 6. Check and clear any Diagnostic Trouble Codes (DTC's) that may have been set. 7. Turn the ignition key to the "OFF" position and remove the StarSCAN(R) unit, StarSCAN(R) cable, and battery charger from the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead Power Distribution Module: Locations Module-Electronic Overhead Component ID: 148 Component : MODULE-ELECTRONIC OVERHEAD Connector: Name : MODULE-ELECTRONIC OVERHEAD C1 Color : BLACK # of pins : 3 A READING/RAIL LAMPS DRIVER M27 20YL/LB B GROUND Z936 20BK/LB C COURTESY LAMPS DRIVER M24 20YL/WT Component Location - 43 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 190 Connector: Name : MODULE-ELECTRONIC OVERHEAD C2 Color : BLACK # of pins : 4 A SUNROOF VENT SWITCH SENSE Q4 20OR/YL B SUNROOF SWITCH SUPPLY Q6 20OR/LG C SUNROOF OPEN SWITCH SENSE Q3 20OR/TN D SUNROOF CLOSE SWITCH SENSE Q5 20OR/LB Component Location - 43 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 191 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 192 Power Distribution Module: Locations Module-Totally Integrated Power Component ID: 163 Component : MODULE-TOTALLY INTEGRATED POWER Connector: Name : MODULE-TOTALLY INTEGRATED POWER C1 Color : BLACK # of pins : 13 Pin Description Circuit 1 REAR WASHER PUMP MOTOR CONTROL W20 20BR/YL 2 FRONT WASHER PUMP MOTOR CONTROL W10 20BR/TN 3 IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4-5-6 CABIN HEATER RELAY 2 CONTROL K232 20BR/LB 7 CABIN HEATER RELAY 1 CONTROL K132 20DB/LB 8-9-10 - 11 - 12 BRAKE FLUID LEVEL SWITCH SENSE B20 20DG/RD 13 GROUND Z924 20BK/LB Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 193 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 194 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C10 Color : LT. GRAY # of pins : 8 Pin Description Circuit 1-2-3 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 4-5 FUSED MAIN RELAY OUTPUT F343 18DB/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 195 6 FUSED MAIN RELAY OUTPUT F344 18DB/LB 7-8 STARTER CONTROL OUTPUT T750 16YL/GY Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 196 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C11 Color : GREEN # of pins : 22 Pin Description Circuit 1 FUSED MAIN RELAY OUTPUT F342 14BR/DG 2-3-4 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 5 FRONT FOG LAMP CONTROL OUTPUT L89 20WT/YL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 197 6 FRONT FOG LAMP CONTROL OUTPUT L90 20WT/OR 7 LOW/HIGH RAD FAN RELAY CONTROL N201 20DB/LG 8 HORN CONTROL OUTPUT X22 20GY/LB 9 HORN CONTROL OUTPUT X21 20GY/YL 10 FRONT WIPER HIGH SPEED CONTROL OUTPUT W4 16BR/LB 11 FUSED B(+) A935 20RD/LB 12 FRONT WIPER LOW SPEED CONTROL OUTPUT W3 16BR/WT 13 FUSED IGNITION SWITCH OUTPUT (RUN) F936 20PK/YL 14 FUSED B(+) (VALVE) A922 14RD/BK 15 - 16 - - 17 FUSED B(+) (PUMP) A921 12RD/DB 18 - 19 FUSED B(+) A931 20RD/WT 20 - 21 GROUND Z971 16BK 22 RAD FAN RELAY CONTROL N112 20DB/OR Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 198 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C2 Color : LT. GRAY # of pins : 14 Pin Description Circuit 1 IGNITION SWITCH OUTPUT (UNLOCK-RUN-START) F901 20PK/RD 2 STARTER CONTROL T752 20DG/OR 3-4 FUEL PUMP CONTROL K31 20DB/BK 4 FUEL PUMP CONTROL K31 20BR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 199 5 FRONT WIPER PARK SWITCH SENSE W7 20BR/DB 6 GROUND Z924 20BK/LB 7 CAN C BUS (+) D265 20WT/BK 8-9-10 IGNITION SWITCH OUTPUT (UNLOCK-RUN-START) F901 20PK/RD 11 HOOD AJAR SWITCH SENSE G70 20VT/LB 12 - 13 GROUND Z925 20BK/YL 14 CAN C BUS (-) D264 20DB/WT Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 200 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C3 Color : BROWN # of pins : 16 Pin Description Circuit 1 CAN C BUS (+) D65 20WT/BK 2 DIAGNOSTIC CAN C (+) D72 20WT/TN 3 CAN B BUS (+) D55 20WT/OR 4 LEFT REAR TURN SIGNAL L63 20DG/RD 5-- Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 201 6 RIGHT REAR TURN SIGNAL L62 20WT/YL 7 STOP LAMP SWITCH OUTPUT L53 20DG/WT 8 PARK LAMP CONTROL OUTPUT L217 20WT/VT 9 CAN C BUS (-) D64 20WT/LB 10 DIAGNOSTIC CAN C (-) D71 20WT/DB 11 CAN B BUS (-) D54 20WT/PK 12 IGNITION SWITCH OUTPUT (START) F961 20PK/LB 13 STOP LAMP CONTROL OUTPUT L55 20WT/OR 14 - 15 RIGHT REAR WHEEL SPEED SENSOR SIGNAL B1 20YL/DB 16 RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY B2 20DG/TN Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 202 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C4 Color : BLACK # of pins : 10 Pin Description Circuit 1 LEFT TURN SIGNAL L61 20WT/RD 2 RIGHT TURN SIGNAL L60 20WT/TN 3 RIGHT HIGH BEAM OUTPUT L34 20WT/GY 4 LEFT LOW BEAM OUTPUT L43 20WT/DB 5-- Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 203 6-7-8 AAT SIGNAL G31 20VT/LG 9 AAT RETURN G931 20VT/DB 10 - Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 204 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C5 Color : BLUE # of pins : 14 Pin Description Circuit 1 HEADLAMP SWITCH OUTPUT L70 20WT/GY 2 RIGHT TURN SIGNAL (OUT) L160 20WT/TN 3 RIGHT LOW BEAM OUTPUT L44 20VT/RD 4 LEFT HIGH BEAM OUTPUT L33 20WT/PK 5 LEFT TURN SIGNAL (OUT) L161 20WT/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 205 6 HEADLAMP SWITCH OUTPUT L7 20WT/VT 6 HEADLAMP SWITCH OUTPUT L7 20WT/YL 7 A/C PRESSURE SENSOR SUPPLY C818 20LB/TN 8 BACKUP LAMP SWITCH SIGNAL T22 20YL/VT 9 HEADLAMP LEVEL SENSOR SIGNAL L131 20WT/LG 10 HEADLAMP LEVEL SENSOR SIGNAL L132 20LG/WT 11 - 12 A/C PRESSURE SENSOR SIGNAL C18 20LB/BR 13 A/C PRESSURE SENSOR GROUND C918 20BK/LB 14 IGNITION SWITCH OUTPUT (START) F962 20PK/BK Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 206 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C6 Color : LT. GRAY # of pins : 13 Pin Description Circuit 1-2-3-4-5 REAR WIPER MOTOR CONTROL W13 20BR/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 207 6-7-8-9-10 - 11 - 12 REAR FOG LAMP CONTROL OUTPUT L239 20WT/DG 13 - Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 208 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C7 Color : LT. GRAY # of pins : 22 Pin Description Circuit 1-2 FUSED B(+) A923 18RD/WT 2 FUSED B(+) A923 20RD/WT 3 FUSED B(+) A924 20DG/WT 4 FUSED B(+) A952 20RD/OR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 209 5 FUSED IGNITION SWITCH OUTPUT (RUN-START) F200 20PK/LB 6 FUSED B(+) A100 18RD/VT 7 FUSED IGNITION SWITCH OUTPUT (RUN) F100 20DG/YL 8-9 FUSED B(+) A933 20RD/LG 10 - 11 FUEL PUMP CONTROL OUTPUT N1 16DB/OR 12 - 13 FUSED B(+) (I.O.D.) A417 20RD/DG 14 - 15 FUSED B(+) (I.O.D.) A418 20RD/BK 16 FUSED B(+) (I.O.D.) A412 20RD/DB 17 FUSED B(+) A16 12RD/BR 18 DOOR LOCK POWER-FUSED B(+) A932 18RD/BR 19 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F996 20PK/YL 20 - 21 IGNITION SWITCH OUTPUT (RUN-ACC) F981 14PK/BR 22 FUSED B(+) A999 18RD/PK Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 210 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C8 Color : BLACK # of pins : 22 Pin Description Circuit 1 BLOWER MOTOR CONTROL C7 12DB/PK 2 FUSED B(+) A927 16RD/GY 3 FUSED B(+) (I.O.D.) A415 20RD/TN 4 FUSED B(+) (I.O.D.) A414 20RD/DG 5 FUSED B(+) (I.O.D.) A416 18RD Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 211 6 FUSED B(+) (I.O.D.) A420 18WT/RD 7 FUSED B(+) A14 12RD/YL 8 FUSED IGNITION SWITCH OUTPUT (RUN) F937 18PK/YL 9 FUSED REAR WINDOW DEFOGGER CONTROL OUTPUT C16 20DB/GY 10 - 11 BACKUP LAMP SWITCH OUTPUT L1 20WT/LG 12 FUSED IGNITION SWITCH OUTPUT (RUN) F929 20PK/RD 13 FUSED B(+) (I.O.D.) A411 20RD/LG 14 FUSED B(+) (I.O.D.) A419 18RD/DG 15 - 16 - - 17 REAR WINDOW DEFOGGER CONTROL OUTPUT C515 12LB/OR 18 FUSED B(+) (I.O.D.) A413 18RD/LB 19 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 20 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F985 18PK/YL 21 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F986 20PK/BK 22 MAIN RELAY OUTPUT K542 12BR/WT Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 212 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C9 Color : # of pins : 1 Pin Description Circuit 1 B(+) A0 6RD Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 213 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 214 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 215 Power Distribution Module: Locations Module-Inverter Component ID: 157 Component : MODULE-INVERTER Connector: Name : MODULE-INVERTER Color : # of pins : 9 Qualifier : (EXCEPT EXPORT) Pin Description Circuit 1 FUSED B(+) A999 16RD/PK 2-3 110 VOLT AC LINE 1 P801 18LG/PK 4 GROUND Z940 14BK/LG 5 INVERTER ENABLE SWITCH SIGNAL P805 18LG/DB 6-- 7-8 110 VOLT AC COMMON P809 18LG/LB 9-Component Location - 24 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 216 Component Location - 26 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 217 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead Power Distribution Module: Diagrams Module-Electronic Overhead Component ID: 148 Component : MODULE-ELECTRONIC OVERHEAD Connector: Name : MODULE-ELECTRONIC OVERHEAD C1 Color : BLACK # of pins : 3 A READING/RAIL LAMPS DRIVER M27 20YL/LB B GROUND Z936 20BK/LB C COURTESY LAMPS DRIVER M24 20YL/WT Component Location - 43 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 220 Connector: Name : MODULE-ELECTRONIC OVERHEAD C2 Color : BLACK # of pins : 4 A SUNROOF VENT SWITCH SENSE Q4 20OR/YL B SUNROOF SWITCH SUPPLY Q6 20OR/LG C SUNROOF OPEN SWITCH SENSE Q3 20OR/TN D SUNROOF CLOSE SWITCH SENSE Q5 20OR/LB Component Location - 43 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 221 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 222 Power Distribution Module: Diagrams Module-Totally Integrated Power Component ID: 163 Component : MODULE-TOTALLY INTEGRATED POWER Connector: Name : MODULE-TOTALLY INTEGRATED POWER C1 Color : BLACK # of pins : 13 Pin Description Circuit 1 REAR WASHER PUMP MOTOR CONTROL W20 20BR/YL 2 FRONT WASHER PUMP MOTOR CONTROL W10 20BR/TN 3 IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4-5-6 CABIN HEATER RELAY 2 CONTROL K232 20BR/LB 7 CABIN HEATER RELAY 1 CONTROL K132 20DB/LB 8-9-10 - 11 - 12 BRAKE FLUID LEVEL SWITCH SENSE B20 20DG/RD 13 GROUND Z924 20BK/LB Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 223 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 224 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C10 Color : LT. GRAY # of pins : 8 Pin Description Circuit 1-2-3 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 4-5 FUSED MAIN RELAY OUTPUT F343 18DB/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 225 6 FUSED MAIN RELAY OUTPUT F344 18DB/LB 7-8 STARTER CONTROL OUTPUT T750 16YL/GY Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 226 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C11 Color : GREEN # of pins : 22 Pin Description Circuit 1 FUSED MAIN RELAY OUTPUT F342 14BR/DG 2-3-4 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 5 FRONT FOG LAMP CONTROL OUTPUT L89 20WT/YL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 227 6 FRONT FOG LAMP CONTROL OUTPUT L90 20WT/OR 7 LOW/HIGH RAD FAN RELAY CONTROL N201 20DB/LG 8 HORN CONTROL OUTPUT X22 20GY/LB 9 HORN CONTROL OUTPUT X21 20GY/YL 10 FRONT WIPER HIGH SPEED CONTROL OUTPUT W4 16BR/LB 11 FUSED B(+) A935 20RD/LB 12 FRONT WIPER LOW SPEED CONTROL OUTPUT W3 16BR/WT 13 FUSED IGNITION SWITCH OUTPUT (RUN) F936 20PK/YL 14 FUSED B(+) (VALVE) A922 14RD/BK 15 - 16 - - 17 FUSED B(+) (PUMP) A921 12RD/DB 18 - 19 FUSED B(+) A931 20RD/WT 20 - 21 GROUND Z971 16BK 22 RAD FAN RELAY CONTROL N112 20DB/OR Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 228 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C2 Color : LT. GRAY # of pins : 14 Pin Description Circuit 1 IGNITION SWITCH OUTPUT (UNLOCK-RUN-START) F901 20PK/RD 2 STARTER CONTROL T752 20DG/OR 3-4 FUEL PUMP CONTROL K31 20DB/BK 4 FUEL PUMP CONTROL K31 20BR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 229 5 FRONT WIPER PARK SWITCH SENSE W7 20BR/DB 6 GROUND Z924 20BK/LB 7 CAN C BUS (+) D265 20WT/BK 8-9-10 IGNITION SWITCH OUTPUT (UNLOCK-RUN-START) F901 20PK/RD 11 HOOD AJAR SWITCH SENSE G70 20VT/LB 12 - 13 GROUND Z925 20BK/YL 14 CAN C BUS (-) D264 20DB/WT Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 230 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C3 Color : BROWN # of pins : 16 Pin Description Circuit 1 CAN C BUS (+) D65 20WT/BK 2 DIAGNOSTIC CAN C (+) D72 20WT/TN 3 CAN B BUS (+) D55 20WT/OR 4 LEFT REAR TURN SIGNAL L63 20DG/RD 5-- Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 231 6 RIGHT REAR TURN SIGNAL L62 20WT/YL 7 STOP LAMP SWITCH OUTPUT L53 20DG/WT 8 PARK LAMP CONTROL OUTPUT L217 20WT/VT 9 CAN C BUS (-) D64 20WT/LB 10 DIAGNOSTIC CAN C (-) D71 20WT/DB 11 CAN B BUS (-) D54 20WT/PK 12 IGNITION SWITCH OUTPUT (START) F961 20PK/LB 13 STOP LAMP CONTROL OUTPUT L55 20WT/OR 14 - 15 RIGHT REAR WHEEL SPEED SENSOR SIGNAL B1 20YL/DB 16 RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY B2 20DG/TN Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 232 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C4 Color : BLACK # of pins : 10 Pin Description Circuit 1 LEFT TURN SIGNAL L61 20WT/RD 2 RIGHT TURN SIGNAL L60 20WT/TN 3 RIGHT HIGH BEAM OUTPUT L34 20WT/GY 4 LEFT LOW BEAM OUTPUT L43 20WT/DB 5-- Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 233 6-7-8 AAT SIGNAL G31 20VT/LG 9 AAT RETURN G931 20VT/DB 10 - Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 234 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C5 Color : BLUE # of pins : 14 Pin Description Circuit 1 HEADLAMP SWITCH OUTPUT L70 20WT/GY 2 RIGHT TURN SIGNAL (OUT) L160 20WT/TN 3 RIGHT LOW BEAM OUTPUT L44 20VT/RD 4 LEFT HIGH BEAM OUTPUT L33 20WT/PK 5 LEFT TURN SIGNAL (OUT) L161 20WT/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 235 6 HEADLAMP SWITCH OUTPUT L7 20WT/VT 6 HEADLAMP SWITCH OUTPUT L7 20WT/YL 7 A/C PRESSURE SENSOR SUPPLY C818 20LB/TN 8 BACKUP LAMP SWITCH SIGNAL T22 20YL/VT 9 HEADLAMP LEVEL SENSOR SIGNAL L131 20WT/LG 10 HEADLAMP LEVEL SENSOR SIGNAL L132 20LG/WT 11 - 12 A/C PRESSURE SENSOR SIGNAL C18 20LB/BR 13 A/C PRESSURE SENSOR GROUND C918 20BK/LB 14 IGNITION SWITCH OUTPUT (START) F962 20PK/BK Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 236 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C6 Color : LT. GRAY # of pins : 13 Pin Description Circuit 1-2-3-4-5 REAR WIPER MOTOR CONTROL W13 20BR/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 237 6-7-8-9-10 - 11 - 12 REAR FOG LAMP CONTROL OUTPUT L239 20WT/DG 13 - Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 238 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C7 Color : LT. GRAY # of pins : 22 Pin Description Circuit 1-2 FUSED B(+) A923 18RD/WT 2 FUSED B(+) A923 20RD/WT 3 FUSED B(+) A924 20DG/WT 4 FUSED B(+) A952 20RD/OR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 239 5 FUSED IGNITION SWITCH OUTPUT (RUN-START) F200 20PK/LB 6 FUSED B(+) A100 18RD/VT 7 FUSED IGNITION SWITCH OUTPUT (RUN) F100 20DG/YL 8-9 FUSED B(+) A933 20RD/LG 10 - 11 FUEL PUMP CONTROL OUTPUT N1 16DB/OR 12 - 13 FUSED B(+) (I.O.D.) A417 20RD/DG 14 - 15 FUSED B(+) (I.O.D.) A418 20RD/BK 16 FUSED B(+) (I.O.D.) A412 20RD/DB 17 FUSED B(+) A16 12RD/BR 18 DOOR LOCK POWER-FUSED B(+) A932 18RD/BR 19 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F996 20PK/YL 20 - 21 IGNITION SWITCH OUTPUT (RUN-ACC) F981 14PK/BR 22 FUSED B(+) A999 18RD/PK Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 240 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C8 Color : BLACK # of pins : 22 Pin Description Circuit 1 BLOWER MOTOR CONTROL C7 12DB/PK 2 FUSED B(+) A927 16RD/GY 3 FUSED B(+) (I.O.D.) A415 20RD/TN 4 FUSED B(+) (I.O.D.) A414 20RD/DG 5 FUSED B(+) (I.O.D.) A416 18RD Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 241 6 FUSED B(+) (I.O.D.) A420 18WT/RD 7 FUSED B(+) A14 12RD/YL 8 FUSED IGNITION SWITCH OUTPUT (RUN) F937 18PK/YL 9 FUSED REAR WINDOW DEFOGGER CONTROL OUTPUT C16 20DB/GY 10 - 11 BACKUP LAMP SWITCH OUTPUT L1 20WT/LG 12 FUSED IGNITION SWITCH OUTPUT (RUN) F929 20PK/RD 13 FUSED B(+) (I.O.D.) A411 20RD/LG 14 FUSED B(+) (I.O.D.) A419 18RD/DG 15 - 16 - - 17 REAR WINDOW DEFOGGER CONTROL OUTPUT C515 12LB/OR 18 FUSED B(+) (I.O.D.) A413 18RD/LB 19 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 20 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F985 18PK/YL 21 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F986 20PK/BK 22 MAIN RELAY OUTPUT K542 12BR/WT Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 242 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C9 Color : # of pins : 1 Pin Description Circuit 1 B(+) A0 6RD Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 243 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 244 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 245 Power Distribution Module: Diagrams Module-Inverter Component ID: 157 Component : MODULE-INVERTER Connector: Name : MODULE-INVERTER Color : # of pins : 9 Qualifier : (EXCEPT EXPORT) Pin Description Circuit 1 FUSED B(+) A999 16RD/PK 2-3 110 VOLT AC LINE 1 P801 18LG/PK 4 GROUND Z940 14BK/LG 5 INVERTER ENABLE SWITCH SIGNAL P805 18LG/DB 6-- 7-8 110 VOLT AC COMMON P809 18LG/LB 9-Component Location - 24 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 246 Component Location - 26 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 247 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Totally Integrated Power Module Power Distribution Module: Description and Operation Totally Integrated Power Module Description DESCRIPTION All of the electrical current distributed throughout this vehicle is directed through the standard equipment Totally Integrated Power Module (TIPM) (1). The molded plastic TIPM housing is located in the left front corner of the engine compartment, just behind the air cleaner housing and the battery. The TIPM housing has a molded plastic cover. The TIPM cover is easily removed for service access and has a convenient fuse and relay layout label affixed to the inside surface of the cover to ensure proper component identification. The TIPM housing is secured to the left inner fender well an indexing pin and one screw. All of the TIPM outputs are through the integral engine compartment wire harness. Operation OPERATION All of the current from the generator cable connection goes to the battery through a 10 gauge fusible link that is secured with a nut to the positive battery terminal at the starter. Internal connection of all the Totally Integrated Power Module (TIPM) circuits is accomplished by an intricate network of hard wiring and bus bars. Refer to Wiring Diagrams for complete circuit diagrams. The fusible link, fuses and relays are available for service replacement. The TIPM unit cannot be repaired and is only serviced as a unit with the engine compartment wire harness. If the TIPM is inoperative or damaged, the engine compartment wire harness assembly must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Totally Integrated Power Module > Page 250 Power Distribution Module: Description and Operation Module-Inverter Description DESCRIPTION The inverter module is located in the instrument panel. The A/C outlet is mounted in the center console. The inverter module provides A/C power for user accessories. The inverter converts the 12 Volt DC from the battery system to a 110 Volt AC output. Operation OPERATION The AC power outlet receives 12 volts from the Totally Integrated Power Module (TIPM) and passes it as an enable signal to the inverter module. The inverter module also receives 12 volts via the TIPM and inverts this to a 110 volt AC output. The enable signal received from the power outlet enables the inverter to convert the received voltage and pass it to the power outlet to power external devices. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Page 251 Power Distribution Module: Testing and Inspection Inverter Module For complete circuit diagrams, refer to the appropriate wiring information. WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Totally Integrated Power Module Power Distribution Module: Service and Repair Totally Integrated Power Module Removal REMOVAL The TIPM (TIPM) is serviced as a unit with the engine compartment wire harness. If any internal circuit of the TIPM or the TIPM housing is faulty or damaged, the entire TIPM and engine compartment wire harness unit must be replaced. Refer to Wiring Diagrams for the locations of the affected connectors. 1. Open hood. 2. Disconnect and isolate the battery negative cable. 3. Disconnect each of the engine compartment wire harness connectors. 4. Remove the fasteners that secure each of the engine compartment wire harness ground eyelets to the vehicle body and chassis components. 5. Disengage each of the retainers that secure the engine compartment wire harness to the vehicle body and chassis components. 6. Disengage and remove the TIPM housing from its mounting bracket. 7. Remove the TIPM and the engine compartment wire harness from the engine compartment as a unit. Installation INSTALLATION The Totally Integrated Power Module (TIPM) is serviced as a unit with the engine compartment wire harness. If any internal circuit of the TIPM or the TIPM housing is faulty or damaged, the entire TIPM and engine compartment wire harness unit must be replaced. NOTE: If the Totally Integrated Power Module (TIPM) is being replaced with a new unit, be certain to transfer each of the fuses and relays from the old TIPM to the proper cavities of the new TIPM. Refer to Wiring Diagrams for the proper TIPM cavity assignments. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Totally Integrated Power Module > Page 254 1. Position the TIPM in the engine compartment. 2. Align the TIPM on its mounting bracket and install. 3. Route the engine compartment wire harness from the TIPM through the engine compartment, engaging each of the harness retainers to the mounting provisions in the vehicle body and chassis components. Refer to Wiring Diagrams for the harness routing and retainer locations. 4. Install and tighten the fasteners that secure each of the engine compartment wire harness ground eyelets to the vehicle body and chassis components. Refer to Wiring Diagrams for the ground eyelet locations. 5. Reconnect each of the engine compartment wire harness connectors. Refer to Wiring Diagrams for the locations of the affected connectors. 6. Torque nut retaining positive battery cable at TIPM to 96 - 141 Nm (85 - 130 in. lbs.). 7. Reconnect the battery negative cable. 8. Close hood. 9. Verify vehicle and system operation. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Totally Integrated Power Module > Page 255 Power Distribution Module: Service and Repair Module-Inverter Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. 1. Disconnect and isolate the negative battery cable. 2. Remove the shift bezel. 3. Remove the center bezel from the instrument panel. 4. Remove the fasteners from the mounting brackets of the inverter module. 5. Disconnect the electrical connectors and remove the inverter module. Installation INSTALLATION 1. Connect the electrical connectors to the inverter module. 2. Install the fasteners to the mounting brackets. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Totally Integrated Power Module > Page 256 3. Install the center bezel to the instrument panel. 4. Install the shift bezel. 5. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Removal Power Distribution Relay: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove cover from Totally Integrated Power module (TIPM). 3. Using special tool C-4817 (1), grip the relay (2) by the sides and pull upward with an even effort. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Removal > Page 261 Power Distribution Relay: Service and Repair Installation INSTALLATION 1. Align relay (2) with Totally Integrated Power Module (TIPM) and press into position. 2. Install cover to TIPM. 3. Connect battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 265 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 266 Relay Box: Application and ID Fuse/Relay Block Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor Engine Control Module: Technical Service Bulletins Engine Controls - MIL On/DTC P0116/ECT Sensor NUMBER: 18-039-06 GROUP: Vehicle Performance DATE: December 6, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES FOR StarSCAN. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 7.02 SP2 OR HIGHER FOR THIS BULLETIN. SUBJECT: Flash: MIL Illumination DTC P0116 - Engine Coolant Temperature Sensor Performance OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) and the Transmission Control Module (1CM) with new software. CAUTION: VEHICLES EQUIPPED WITH A CVT TRANSMISSION MUST HAVE THE TRANSMISSION CONTROL MODULE (TCM) CHECKED FOR THE LATEST SOFTWARE LEVEL WHENEVER THE PCM SOFTWARE IS UPGRADED. IF NEWER TCM SOFTWARE IS AVAILABLE, IT MUST BE INSTALLED. MODELS: 2007 (PM) Caliber 2007 (MK49) Compass NOTE: This bulletin applies to PM/MK models equipped with a 1.8L, 2.0L or 2.4L gasoline engine (Sales Code EBA, ECN or ED3) and block heater (Sales Code NHK) built before November 20, 2006 (MDH 1120XX). NOTE: If an aftermarket or MOPAR accessory block heater is installed, the same conditions may apply. SYMPTOM/CONDITION: Some customers may experience MIL illumination after using the block heater. No other symptoms will be experienced. The technician may find the following DTC's: ^ P0116 - ENGINE COOLANT TEMPERATURE SENSOR PERFORMANCE DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If MIL illumination with DTC P0116 is present, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 273 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING **STEP 5n and/or 8h**. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 7.02 SP2 software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. PM/MK Models equipped with a CVT must have the TCM reprogrammed as follows: 6. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. 7. Is the TCM part number recorded in step 6e above, the same as the new p/n shown on the "Flash File List" screen? a. Yes >> No further action is necessary. Proceed to Step 9. b. No >> the TCM will require flash reprogramming, proceed to Step 8. 8. Flash reprogram the TCM as follows: a. From the "Flash File List" screen, select "Download to Scantool". b. Select "Close" after the download is complete, then select "Back". c. Highlight the listed calibration. d. Select "Update Controller". Follow on screen instructions. e. When the update is complete, select "OK". f. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. g. Turn the ignition switch to the OFF position for no less than 15 seconds. h. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 274 CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the TCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. ** NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 9. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 275 Engine Control Module: Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 276 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 277 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 278 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 279 Engine Control Module: Locations Component ID: 160 Component : MODULE-POWERTRAIN CONTROL Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK # of pins : 58 Qualifier : (GAS) Pin Description Circuit 1 FUSED MAIN RELAY OUTPUT F342 14BR/DG 2 GROUND Z925 16BK/YL 3 FUSED MAIN RELAY OUTPUT F342 14BR/DG 4 GROUND Z925 16BK/YL 5-6-- 7 O2 1/2 HEATER CONTROL K299 20BR/RD 8-9-10 - 11 - 12 - 13 S/C SWITCH GROUND V937 20VT/BR 14 - 15 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 16 FUSED B(+) A931 20RD/WT 17 - 18 - 19 FUEL PUMP CONTROL K31 20BR 20 O2 1/2 RETURN K904 20DB/DG 21 O2 1/2 SIGNAL K141 20DB/YL 22 5 VOLT SUPPLY K858 20BR/GY 23 5 VOLT SUPPLY F856 20YL/PK 24 - 25 STARTER CONTROL T752 20DG/OR 26 S/C SIGNAL 2 V72 20OR/VT 27 S/C SIGNAL 1 V71 20VT/OR 28 - 29 - 30 SENSOR GROUND K914 20DB/PK 31 - 32 BRAKE SIGNAL 1 B15 20DG/WT 33 - 34 APP SENSOR GROUND 2 K400 20BR/VT Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 280 35 EVAP PURGE RETURN K70 20DB/BR 36 APP SENSOR GROUND 1 K167 20BR/YL 37 START ENABLE F963 20PK/DB 38 VEHICLE SPEED SIGNAL K75 20DB/OR 39 EVAP PURGE CONTROL K52 20DB/WT 40 - 41 CAN C BUS (+) D65 20WT/BK 42 - 43 - 44 - 45 - - 46 - 47 ESM SIGNAL K107 20VT/WT 48 APP SIGNAL 2 K29 20WT/BR 49 APP SIGNAL 1 K23 20BR/OR 50 CLUTCH INTERLOCK SIGNAL T141 20YL/RD 51 - 52 BRAKE SIGNAL 2 B16 20LB/DG 53 GEN SENSE A804 20RD/GY 54 CAN C BUS (-) D64 20WT/LB 55 - 56 - 57 - 58 MAIN RELAY CONTROL K51 20BR/LG Component Location - 8 Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 281 Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 282 Connector: Name : MODULE-POWERTRAIN CONTROL C2 Color : BLACK # of pins : 96 Qualifier : (GAS) Pin Description Circuit 1 ETC MOTOR (+) K124 20DB/GY 2-3-4-- Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 283 5-- 6 A/C COMPRESSOR CONTROL C27 20LB/WT 7-8 IAT SIGNAL K21 20BK/RD 9-10 - 11 ECT 2 SIGNAL K222 20BR/YL 12 - 13 - 14 - 15 - 16 - 17 - 18 - 19 - 20 - 21 INJECTOR 3 CONTROL K13 20BR/LB 22 INJECTOR 4 CONTROL K14 20BR/TN 23 INJECTOR 1 CONTROL K11 20YL/BR 24 INJECTOR 2 CONTROL K12 20BR/DB 25 ETC MOTOR (-) K126 20DB/LG 26 - 27 MFV CONTROL K601 20BR/VT 28 - 29 - 30 - 31 - 32 - 33 O2 1/1 SIGNAL K41 20BK/DG 34 - 35 - 36 O2 1/1 RETURN K902 20BR/DG 37 EOT SIGNAL G24 20VT/BR 38 CMP 1/2 SIGNAL K441 20DB/BR 39 - 40 - 41 5 VOLT SUPPLY F855 20PK/YL 42 5 VOLT SUPPLY K857 20BR/LG 43 - 44 - 45 - 46 - 47 - 48 - 49 O2 1/1 HEATER CONTROL K99 20BR/OR 50 - 51 GEN FIELD CONTROL K20 20BR/GY 52 - 53 - 54 - 55 - 56 - 57 CMP 1/1 SIGNAL K44 20DB 58 SENSOR GROUND K915 20BR/WT 59 - 60 - 61 - 62 TP SENSOR GROUND K922 20BR 63 TP SIGNAL 2 K122 20DG/BR 64 TP SIGNAL 1 K22 20OR/BR 65 KS RETURN K942 20WT/BR 66 - 67 - - 68 - 69 - 70 CMP 1/1 CONTROL K76 20LB/WT Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 284 71 - 72 CMP 1/2 CONTROL K276 20DB/WT 73 COIL 4 CONTROL K15 18GY/DB 74 COIL 3 CONTROL K18 18DB/OR 75 COIL 2 CONTROL K17 18DB/TN 76 COIL 1 CONTROL K19 18DG/LB 77 - 78 - 79 CKP SIGNAL K24 20LB/BR 80 - 81 - - 82 SENSOR GROUND K900 20DB/DG 83 ECT 1 SIGNAL K2 20VT/OR 84 MFV SIGNAL K602 20YL/DB 85 MAP SIGNAL K1 20VT/LB 86 EOP SIGNAL G6 20VT/GY 87 - 88 KS SIGNAL K42 20LG/DB 89 - 90 - 91 - 92 - 93 - 94 - 95 - 96 - Component Location - 8 Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 285 Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 286 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: Provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 289 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 290 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 291 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 292 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 293 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 294 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 295 5. Release the Secondary Terminal Lock, if required (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 296 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 297 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 298 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 299 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 300 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 301 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 302 Engine Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 303 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 304 STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 305 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 306 Engine Control Module: Connector Views Component ID: 160 Component : MODULE-POWERTRAIN CONTROL Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK # of pins : 58 Qualifier : (GAS) Pin Description Circuit 1 FUSED MAIN RELAY OUTPUT F342 14BR/DG 2 GROUND Z925 16BK/YL 3 FUSED MAIN RELAY OUTPUT F342 14BR/DG 4 GROUND Z925 16BK/YL 5-6-- 7 O2 1/2 HEATER CONTROL K299 20BR/RD 8-9-10 - 11 - 12 - 13 S/C SWITCH GROUND V937 20VT/BR 14 - 15 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 16 FUSED B(+) A931 20RD/WT 17 - 18 - 19 FUEL PUMP CONTROL K31 20BR 20 O2 1/2 RETURN K904 20DB/DG 21 O2 1/2 SIGNAL K141 20DB/YL 22 5 VOLT SUPPLY K858 20BR/GY 23 5 VOLT SUPPLY F856 20YL/PK 24 - 25 STARTER CONTROL T752 20DG/OR 26 S/C SIGNAL 2 V72 20OR/VT 27 S/C SIGNAL 1 V71 20VT/OR 28 - 29 - 30 SENSOR GROUND K914 20DB/PK 31 - 32 BRAKE SIGNAL 1 B15 20DG/WT 33 - 34 APP SENSOR GROUND 2 K400 20BR/VT Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 307 35 EVAP PURGE RETURN K70 20DB/BR 36 APP SENSOR GROUND 1 K167 20BR/YL 37 START ENABLE F963 20PK/DB 38 VEHICLE SPEED SIGNAL K75 20DB/OR 39 EVAP PURGE CONTROL K52 20DB/WT 40 - 41 CAN C BUS (+) D65 20WT/BK 42 - 43 - 44 - 45 - - 46 - 47 ESM SIGNAL K107 20VT/WT 48 APP SIGNAL 2 K29 20WT/BR 49 APP SIGNAL 1 K23 20BR/OR 50 CLUTCH INTERLOCK SIGNAL T141 20YL/RD 51 - 52 BRAKE SIGNAL 2 B16 20LB/DG 53 GEN SENSE A804 20RD/GY 54 CAN C BUS (-) D64 20WT/LB 55 - 56 - 57 - 58 MAIN RELAY CONTROL K51 20BR/LG Component Location - 8 Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 308 Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 309 Connector: Name : MODULE-POWERTRAIN CONTROL C2 Color : BLACK # of pins : 96 Qualifier : (GAS) Pin Description Circuit 1 ETC MOTOR (+) K124 20DB/GY 2-3-4-- Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 310 5-- 6 A/C COMPRESSOR CONTROL C27 20LB/WT 7-8 IAT SIGNAL K21 20BK/RD 9-10 - 11 ECT 2 SIGNAL K222 20BR/YL 12 - 13 - 14 - 15 - 16 - 17 - 18 - 19 - 20 - 21 INJECTOR 3 CONTROL K13 20BR/LB 22 INJECTOR 4 CONTROL K14 20BR/TN 23 INJECTOR 1 CONTROL K11 20YL/BR 24 INJECTOR 2 CONTROL K12 20BR/DB 25 ETC MOTOR (-) K126 20DB/LG 26 - 27 MFV CONTROL K601 20BR/VT 28 - 29 - 30 - 31 - 32 - 33 O2 1/1 SIGNAL K41 20BK/DG 34 - 35 - 36 O2 1/1 RETURN K902 20BR/DG 37 EOT SIGNAL G24 20VT/BR 38 CMP 1/2 SIGNAL K441 20DB/BR 39 - 40 - 41 5 VOLT SUPPLY F855 20PK/YL 42 5 VOLT SUPPLY K857 20BR/LG 43 - 44 - 45 - 46 - 47 - 48 - 49 O2 1/1 HEATER CONTROL K99 20BR/OR 50 - 51 GEN FIELD CONTROL K20 20BR/GY 52 - 53 - 54 - 55 - 56 - 57 CMP 1/1 SIGNAL K44 20DB 58 SENSOR GROUND K915 20BR/WT 59 - 60 - 61 - 62 TP SENSOR GROUND K922 20BR 63 TP SIGNAL 2 K122 20DG/BR 64 TP SIGNAL 1 K22 20OR/BR 65 KS RETURN K942 20WT/BR 66 - 67 - - 68 - 69 - 70 CMP 1/1 CONTROL K76 20LB/WT Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 311 71 - 72 CMP 1/2 CONTROL K276 20DB/WT 73 COIL 4 CONTROL K15 18GY/DB 74 COIL 3 CONTROL K18 18DB/OR 75 COIL 2 CONTROL K17 18DB/TN 76 COIL 1 CONTROL K19 18DG/LB 77 - 78 - 79 CKP SIGNAL K24 20LB/BR 80 - 81 - - 82 SENSOR GROUND K900 20DB/DG 83 ECT 1 SIGNAL K2 20VT/OR 84 MFV SIGNAL K602 20YL/DB 85 MAP SIGNAL K1 20VT/LB 86 EOP SIGNAL G6 20VT/GY 87 - 88 KS SIGNAL K42 20LG/DB 89 - 90 - 91 - 92 - 93 - 94 - 95 - 96 - Component Location - 8 Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 312 Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 313 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description Engine Control Module: Description and Operation Description PCM Ground PCM GROUND Ground is provided through multiple pins of the PCM connector. Depending on the vehicle there may be as many as two different ground pins. There are power grounds and sensor grounds. The power grounds are used to control the ground side relays, solenoids, ignition coil or injectors. The signal ground is used for any input that uses sensor return for ground, and the ground side of any internal processing component. The PCM case is shielded to prevent RFI and EMI. The PCM case is grounded and must be firmly attached to a good, clean body ground. Internally all grounds are connected together, however there is noise suppression on the sensor ground. For EMI and RFI protection the housing and cover are also grounded separately from the ground pins. Sensor Return - PCM Input SENSOR RETURN - PCM INPUT The sensor return circuit provides a low electrical noise ground reference for all of the systems sensors. The sensor return circuit connects to internal ground circuits within the Powertrain Control Module (PCM). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description > Page 316 Engine Control Module: Description and Operation Operation Powertrain Control Module POWERTRAIN CONTROL MODULE The PCM receives input signals from various switches and sensors that are referred to as PCM Inputs. Based on these inputs, the PCM adjusts various engine and vehicle operations through devices that are referred to as PCM Outputs. NOTE: PCM Inputs: - Air Conditioning Controls - Battery Voltage - Brake Switch - Camshaft Position Sensor - Clutch Upstop Switch - Clutch Interlock - Crankshaft Position Sensor - Engine Coolant Temperature Sensor - Fuel Level Sensor (Bus message) - Ignition Switch - Intake Air Temperature Sensor - Knock Sensor - Evaporative System Integrity Monitor - Manifold Absolute Pressure (MAP) Sensor - Oil Pressure Switch - Oxygen Sensors - Power Steering Pressure Switch - Speed Control Switches - Vehicle Speed Sensor (MTX-equipped models) NOTE: PCM Outputs: - Air Conditioning Clutch Relay - Charging Indicator Lamp (Bus Message) - Proportional Purge Solenoid - Fuel Injectors - Generator Field - Ignition Coils - Malfunction Indicator (Check Engine) Lamp (Bus Message) - Manifold Flow Valve - Oxygen Sensors Heater Controls - Variable Valve Timing - Vehicle Speed (Manual Transmission) Based on inputs it receives, the PCM adjusts fuel injector pulse width, idle speed, ignition spark advance, ignition coil dwell and EVAP canister purge operation. The PCM also determines the appropriate transmission shift schedule and shift points, depending on the present operating conditions and driver demand. The PCM regulates the cooling fan, air conditioning and speed control systems. The PCM changes generator charge rate by adjusting the Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description > Page 317 generator field. The PCM also performs diagnostics. The PCM adjusts injector pulse width (air-fuel ratio) based on the following inputs. - Battery voltage - Coolant temperature - Exhaust gas content (oxygen sensor) - Engine speed (crankshaft position sensor) - Intake air temperature - Manifold absolute pressure - Throttle position The PCM adjusts ignition timing based on the following inputs. - Coolant temperature - Engine speed (crankshaft position sensor) - Knock sensor - Manifold absolute pressure - Throttle position - Transmission gear selection (park/neutral switch) - Intake air temperature The PCM also adjusts engine idle speed through the idle air control motor based on the following inputs. - Air conditioning sense - Battery voltage - Brake switch - Coolant temperature - Engine speed (crankshaft position sensor) - Engine run time - Manifold absolute pressure - Power steering pressure switch - Throttle position - Transmission gear selection (park/neutral switch) - Vehicle distance (speed) The camshaft position sensor and crankshaft position sensor signals are sent to the PCM. If the PCM does not receive the signal within approximately 1 second of engine cranking, it deactivates the fuel pump. When these are deactivated, power is shut off to the fuel injectors, ignition coils, oxygen sensor heating elements and fuel pump. The PCM contains a voltage converter that changes battery voltage to a regulated 5 volt direct current to power the camshaft position sensor, crankshaft position sensor, manifold absolute pressure sensor, throttle position sensor, A/C pressure switch, A/C pressure transducer, and vehicle speed sensor. 5 Volt Supply - PCM Output 5 VOLT SUPPLY - PCM OUTPUT The PCM supplies 5 volts to the following sensors: - A/C pressure transducer - Ambient Temperature sensor - Battery temperature - Camshaft Position Sensor (NGC) - Crankshaft Position Sensor (NGC) - Engine coolant temperature sensor - Inlet Air Temperature Sensor - Knock sensor - Linear EGR solenoid (if equipped) - Manifold absolute pressure sensor - Oil Pressure Switch Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM/SKREEM Programming Engine Control Module: Testing and Inspection PCM/ECM/SKREEM Programming PCM/ECM/SKREEM PROGRAMMING NOTE: Before replacing the Powertrain Control Module (PCM) or Engine Control Module (ECM), be certain to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most PCM/ECM driver/control circuit failures are caused by internal component failures (i.e. relays and solenoids) and shorted circuits (i.e. pull-ups, drivers, and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has been set. When a PCM, or ECM, and the Sentry Key REmote Entry Module (SKREEM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: 1. Program the new PCM or ECM. 2. Program the new SKREEM (also sometimes referred to as the Wireless Control Module or WCM). 3. Replace all ignition keys and program them into the new SKREEM/WCM. PROGRAMMING THE SKREEM The SKIS Secret Key is an ID code that is unique to each SKREEM/WCM. This code is programmed and stored in the SKREEM/WCM, the PCM/ECM, and each ignition key transponder chip. When the PCM or SKREEM/WCM is replaced, it is necessary to program the Secret Key into the new module using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool for "PCM Replaced" or "WCM Replaced" under "Miscellaneous Functions" for the "WCM/Wireless Control Module" menu item as appropriate. NOTE: If the PCM/ECM and the SKREEM/WCM are replaced at the same time, all vehicle ignition keys will need to be replaced and new keys programmed into the new SKREEM/WCM. NOTE: Programming the PCM/ECM or SKREEM is done using a diagnostic scan tool and a PIN to enter secure access mode. If eight attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. (Ensure all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary). PROGRAMMING IGNITION KEYS TO THE SKREEM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKREEM/WCM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKREEM/WCM. To program ignition keys into the SKREEM/WCM, follow the programming steps outlined in the diagnostic scan tool for PROGRAM IGNITION KEYS OR KEY FOBS under MISCELLANEOUS FUNCTIONS for the WCM/WIRELESS CONTROL MODULE menu item. NOTE: A maximum of eight keys can be learned to each SKREEM. Once a key is learned to a SKREEM, that key has acquired the Secret Key for that SKREEM and cannot be transferred to any other SKREEM or vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: - Programming Not Attempted - The scan tool attempts to read the programmed key status and there are no keys programmed into SKREEM memory. - Programming Key Failed (Possible Used Key From Wrong Vehicle) - SKREEM is unable to program an ignition key transponder due to one of the following: - The ignition key transponder is faulty. - The ignition key transponder is or has been already programmed to another vehicle. - 8 Keys Already Learned, Programming Not Done - The SKREEM transponder ID memory is full. - Learned Key In Ignition - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKREEM memory. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM/SKREEM Programming > Page 320 Engine Control Module: Testing and Inspection Pinion Factor Setting PINION FACTOR SETTING NOTE: This procedure must be performed if the PCM has been replaced with a NEW or replacement unit. Failure to perform this procedure will result in an inoperative or improperly calibrated speedometer. The vehicle speed readings for the speedometer are taken from the output speed sensor. The PCM must be calibrated to the different combinations of equipment (final drive and tires) available. Pinion Factor allows the technician to set the Powertrain Control Module initial setting so that the speedometer readings will be correct. To properly read and/or reset the Pinion Factor, it is necessary to use a scan tool. 1. Plug the scan tool into the diagnostic connector located under the instrument panel. 2. Select the Transmission menu. 3. Select the Miscellaneous menu. 4. Select Pinion Factor. Then follow the instructions on the scan tool screen. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal Engine Control Module: Service and Repair Removal REMOVAL USE THE SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM) WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (VIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. To avoid possible voltage spike damage to PCM, ignition key must be off, and negative battery cable must be disconnected before unplugging PCM connectors. 1. Disconnect negative battery cable. 2. Unlock and disconnect the electrical connectors from PCM. 3. Remove the air cleaner box. 4. Remove the three mounting bolts. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal > Page 323 5. Tip module out and remove from bracket. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal > Page 324 Engine Control Module: Service and Repair Installation INSTALLATION USE THE SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM) WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (VIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. 1. Tip module into bracket. 2. Install three mounting bolts and tighten to 9 Nm (80 in. lbs.) torque. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal > Page 325 3. Check pins in electrical connectors for damage. Repair as necessary. 4. Connect electrical connectors and lock. 5. Install air cleaner box. 6. Connect negative battery cable. 7. Use the scan tool to reprogram new PCM with vehicles original Identification Number (VIN) and original vehicle mileage. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Main Relay is located in the Fuse/Relay block. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 329 Main Relay (Computer/Fuel System): Diagrams Component ID: 182 Component : RELAY-MAIN Connector: Name : RELAY-MAIN Color : # of pins : 0 B6 FUSED B(+) A14 12RD/YL B7 MAIN RELAY OUTPUT K542 12BR/WT B8 - B9 FUSED B(+) A14 12RD/YL B10 MAIN RELAY CONTROL K51 20BR/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Main Relay is located in the Fuse/Relay block. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 334 Main Relay (Computer/Fuel System): Diagrams Component ID: 182 Component : RELAY-MAIN Connector: Name : RELAY-MAIN Color : # of pins : 0 B6 FUSED B(+) A14 12RD/YL B7 MAIN RELAY OUTPUT K542 12BR/WT B8 - B9 FUSED B(+) A14 12RD/YL B10 MAIN RELAY CONTROL K51 20BR/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Module-Occupant Classification Air Bag Control Module: Locations Module-Occupant Classification Component ID: 158 Component : MODULE-OCCUPANT CLASSIFICATION Connector: Name : MODULE-OCCUPANT CLASSIFICATION C1 Color : BLACK # of pins : 10 Qualifier : (EXCEPT EXPORT) Pin Description Circuit 1 FUSED B(+) (I.O.D.) A417 18RD 2-3-4 CAN B BUS (+) D55 20WT/OR 5 CAN B BUS (-) D54 20WT 6-- 7 DRIVER SEAT POSITION SENSOR VOLTAGER263 20LB/VT 8-9 DRIVER SEAT POSITION SENSOR DATA R261 20LB/WT 10 GROUND Z944 20BK Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Module-Occupant Classification > Page 340 Connector: Name : MODULE-OCCUPANT CLASSIFICATION C2 Color : BLACK # of pins : 12 Qualifier : (EXCEPT EXPORT) Pin Description Circuit 1 SEAT WEIGHT SENSOR 5 VOLT R701 20LG 2 PASSENGER SEAT POSITION SENSOR VOLTAGE R264 20VT/LB 3 SEAT WEIGHT LEFT FRONT SENSOR SIGNAL R717 20LG/DG 4-- Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Module-Occupant Classification > Page 341 5 SEAT WEIGHT RIGHT FRONT SENSOR SIGNAL R718 20LB/DG 6-7 SEAT WEIGHT RIGHT REAR SENSOR SIGNAL R706 20LB/OR 8-9 SEAT WEIGHT LEFT REAR SENSOR SIGNALR705 20LG/OR 10 - 11 PASSENGER SEAT POSITION SENSOR DATAR262 20WT/LB 12 SEAT WEIGHT SENSOR GROUND R728 20LB/YL Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Module-Occupant Classification > Page 342 Air Bag Control Module: Locations Module-Occupant Restraint Controller Component ID: 159 Component : MODULE-OCCUPANT RESTRAINT CONTROLLER Connector: Name : MODULE-OCCUPANT RESTRAINT CONTROLLER C1 (ORC) Color : YELLOW # of pins : 24 Pin Description Circuit 1-2-3 CAN B BUS (+) D55 20WT/OR 4 CAN B BUS (-) D54 20WT/PK 5-6-7-- 8-9 LEFT FRONT IMPACT SENSOR GROUND R81 20LB/WT 10 LEFT FRONT IMPACT SENSOR SIGNAL R79 20LB/VT 11 RIGHT FRONT IMPACT SENSOR GROUND R82 20WT/OR 12 RIGHT FRONT IMPACT SENSOR SIGNAL R80 20VT/LB 13 DRIVER KNEE BLOCKER SQUIB LINE 2 R9 18LB/YL 14 DRIVER KNEE BLOCKER SQUIB LINE 1 R11 18LB/DB 15 - 16 - 17 DRIVER SQUIB 1 LINE 2 R43 18LG/BR 18 DRIVER SQUIB 1 LINE 1 R45 18LG/RD 19 PASSENGER SQUIB 1 LINE 1 R44 18LB/OR 20 PASSENGER SQUIB 1 LINE 2 R42 18LB/BR 21 DRIVER SQUIB 2 LINE 2 R61 18LG/VT 22 DRIVER SQUIB 2 LINE 1 R63 18LG/BK 23 PASSENGER SQUIB 2 LINE 1 R64 18LB/WT 24 PASSENGER SQUIB 2 LINE 2 R62 18LB/VT Component Location - 45 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Module-Occupant Classification > Page 343 Component Location - 46 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Module-Occupant Classification > Page 344 Connector: Name : MODULE-OCCUPANT RESTRAINT CONTROLLER C2 (ORC) Color : YELLOW # of pins : 32 Pin Description Circuit 1-2-3-4-5 LEFT CURTAIN SQUIB 1 LINE 2 R1 18LB/WT Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Module-Occupant Classification > Page 345 6 LEFT CURTAIN SQUIB 1 LINE 1 R3 18LB/OR 7 RIGHT CURTAIN SQUIB 1 LINE 1 R4 18OR/LB 8 RIGHT CURTAIN SQUIB 1 LINE 2 R2 18WT/LB 9 DRIVER SEAT BELT TENSIONER LINE 2 R53 18LG/YL 10 DRIVER SEAT BELT TENSIONER LINE 1 R55 18LG/DG 11 PASSENGER SEAT BELT TENSIONER LINE 1R56 18LB/DG 12 PASSENGER SEAT BELT TENSIONER LINE 2R54 18LB/YL 13 - 14 - 15 - 16 - - 17 FUSED IGNITION SWITCH OUTPUT (RUN-START) F200 20PK/LB 18 FUSED IGNITION SWITCH OUTPUT (RUN) F100 20DG/YL 19 - 20 GROUND Z944 18BK/LG 21 PASSENGER HALL EFFECT (-) R272 20LB/VT 22 - 23 - 24 PASSENGER HALL EFFECT (+) R274 20LB/WT 25 - 26 - 27 RIGHT SIDE IMPACT SENSOR 1 SIGNAL R14 20TN/LG 28 RIGHT SIDE IMPACT SENSOR 1 GROUND R16 20BR/LG 29 LEFT SIDE IMPACT SENSOR 1 GROUND R15 20LG/BR 30 LEFT SIDE IMPACT SENSOR 1 SIGNAL R13 20LG/TN 31 - 32 - Component Location - 45 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Module-Occupant Classification > Page 346 Component Location - 46 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Module-Occupant Classification Air Bag Control Module: Diagrams Module-Occupant Classification Component ID: 158 Component : MODULE-OCCUPANT CLASSIFICATION Connector: Name : MODULE-OCCUPANT CLASSIFICATION C1 Color : BLACK # of pins : 10 Qualifier : (EXCEPT EXPORT) Pin Description Circuit 1 FUSED B(+) (I.O.D.) A417 18RD 2-3-4 CAN B BUS (+) D55 20WT/OR 5 CAN B BUS (-) D54 20WT 6-- 7 DRIVER SEAT POSITION SENSOR VOLTAGER263 20LB/VT 8-9 DRIVER SEAT POSITION SENSOR DATA R261 20LB/WT 10 GROUND Z944 20BK Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Module-Occupant Classification > Page 349 Connector: Name : MODULE-OCCUPANT CLASSIFICATION C2 Color : BLACK # of pins : 12 Qualifier : (EXCEPT EXPORT) Pin Description Circuit 1 SEAT WEIGHT SENSOR 5 VOLT R701 20LG 2 PASSENGER SEAT POSITION SENSOR VOLTAGE R264 20VT/LB 3 SEAT WEIGHT LEFT FRONT SENSOR SIGNAL R717 20LG/DG 4-- Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Module-Occupant Classification > Page 350 5 SEAT WEIGHT RIGHT FRONT SENSOR SIGNAL R718 20LB/DG 6-7 SEAT WEIGHT RIGHT REAR SENSOR SIGNAL R706 20LB/OR 8-9 SEAT WEIGHT LEFT REAR SENSOR SIGNALR705 20LG/OR 10 - 11 PASSENGER SEAT POSITION SENSOR DATAR262 20WT/LB 12 SEAT WEIGHT SENSOR GROUND R728 20LB/YL Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Module-Occupant Classification > Page 351 Air Bag Control Module: Diagrams Module-Occupant Restraint Controller Component ID: 159 Component : MODULE-OCCUPANT RESTRAINT CONTROLLER Connector: Name : MODULE-OCCUPANT RESTRAINT CONTROLLER C1 (ORC) Color : YELLOW # of pins : 24 Pin Description Circuit 1-2-3 CAN B BUS (+) D55 20WT/OR 4 CAN B BUS (-) D54 20WT/PK 5-6-7-- 8-9 LEFT FRONT IMPACT SENSOR GROUND R81 20LB/WT 10 LEFT FRONT IMPACT SENSOR SIGNAL R79 20LB/VT 11 RIGHT FRONT IMPACT SENSOR GROUND R82 20WT/OR 12 RIGHT FRONT IMPACT SENSOR SIGNAL R80 20VT/LB 13 DRIVER KNEE BLOCKER SQUIB LINE 2 R9 18LB/YL 14 DRIVER KNEE BLOCKER SQUIB LINE 1 R11 18LB/DB 15 - 16 - 17 DRIVER SQUIB 1 LINE 2 R43 18LG/BR 18 DRIVER SQUIB 1 LINE 1 R45 18LG/RD 19 PASSENGER SQUIB 1 LINE 1 R44 18LB/OR 20 PASSENGER SQUIB 1 LINE 2 R42 18LB/BR 21 DRIVER SQUIB 2 LINE 2 R61 18LG/VT 22 DRIVER SQUIB 2 LINE 1 R63 18LG/BK 23 PASSENGER SQUIB 2 LINE 1 R64 18LB/WT 24 PASSENGER SQUIB 2 LINE 2 R62 18LB/VT Component Location - 45 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Module-Occupant Classification > Page 352 Component Location - 46 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Module-Occupant Classification > Page 353 Connector: Name : MODULE-OCCUPANT RESTRAINT CONTROLLER C2 (ORC) Color : YELLOW # of pins : 32 Pin Description Circuit 1-2-3-4-5 LEFT CURTAIN SQUIB 1 LINE 2 R1 18LB/WT Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Module-Occupant Classification > Page 354 6 LEFT CURTAIN SQUIB 1 LINE 1 R3 18LB/OR 7 RIGHT CURTAIN SQUIB 1 LINE 1 R4 18OR/LB 8 RIGHT CURTAIN SQUIB 1 LINE 2 R2 18WT/LB 9 DRIVER SEAT BELT TENSIONER LINE 2 R53 18LG/YL 10 DRIVER SEAT BELT TENSIONER LINE 1 R55 18LG/DG 11 PASSENGER SEAT BELT TENSIONER LINE 1R56 18LB/DG 12 PASSENGER SEAT BELT TENSIONER LINE 2R54 18LB/YL 13 - 14 - 15 - 16 - - 17 FUSED IGNITION SWITCH OUTPUT (RUN-START) F200 20PK/LB 18 FUSED IGNITION SWITCH OUTPUT (RUN) F100 20DG/YL 19 - 20 GROUND Z944 18BK/LG 21 PASSENGER HALL EFFECT (-) R272 20LB/VT 22 - 23 - 24 PASSENGER HALL EFFECT (+) R274 20LB/WT 25 - 26 - 27 RIGHT SIDE IMPACT SENSOR 1 SIGNAL R14 20TN/LG 28 RIGHT SIDE IMPACT SENSOR 1 GROUND R16 20BR/LG 29 LEFT SIDE IMPACT SENSOR 1 GROUND R15 20LG/BR 30 LEFT SIDE IMPACT SENSOR 1 SIGNAL R13 20LG/TN 31 - 32 - Component Location - 45 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Module-Occupant Classification > Page 355 Component Location - 46 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > Description Air Bag Control Module: Description and Operation Description DESCRIPTION The Occupant Restraint Controller (ORC) (4) is sometimes referred to as the Airbag Control Module (ACM). The ORC is mounted on the tunnel floor pan in front of the transmission floor shifter. The Occupant Restraint Controller (ORC) is secured with three nuts to a stamped steel mounting bracket welded onto the top of the floor panel transmission tunnel beneath the instrument panel floor console. Concealed within a hollow in the center of the die cast aluminum ORC housing is the electronic circuitry of the ORC which includes a microprocessor, an electronic impact sensor, an electronic safing sensor, and an energy storage capacitor. A stamped metal cover plate is secured to the bottom of the ORC housing with four screws to enclose and protect the internal electronic circuitry and components. An arrow printed on the label on the top of the ORC housing provides a visual verification of the proper orientation of the unit, and should always be pointed toward the front of the vehicle. The ORC housing has integral mounting flanges on three of the four corners. Two electrical connectors exit the rearward facing side of the ORC housing. These connect the ORC to the vehicle electrical system, one from the instrument panel wire harness and the second from the body wire harness. The impact sensor and safing sensor internal to the ORC are calibrated for the specific vehicle, and are only serviced as a unit with the ORC. In addition, there are unique versions of the ORC for vehicles with or without the optional side airbags. The ORC cannot be repaired or adjusted and, if damaged or ineffective, it must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > Description > Page 358 Air Bag Control Module: Description and Operation Operation OPERATION The microprocessor in the Occupant Restraint Controller (ORC), sometimes referred to as the Airbag Control Module (ACM), contains the supplemental restraint system logic circuits and controls all of the supplemental restraint system components. The ORC uses On-Board Diagnostics (OBD) and can communicate with other electronic modules in the vehicle as well as with the diagnostic scan tool using the Controller Area Network (CAN) data bus. This method of communication is used for control of the airbag indicator in the Electromechanical Instrument Cluster (EMIC) sometimes referred to as the Cab Compartment Node (CCN), and for supplemental restraint system diagnosis and testing through the 16-way data link connector located on the driver side lower edge of the instrument panel. The ORC microprocessor continuously monitors all of the supplemental restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets an active and stored Diagnostic Trouble Code (DTC) and sends electronic messages to the EMIC/CCN over the CAN data bus to turn ON the airbag indicator. An active fault only remains for the duration of the fault, or in some cases for the duration of the current ignition switch cycle, while a stored fault causes a DTC to be stored in memory by the ORC. For some DTC's, if a fault does not recur for a number of ignition cycles, the ORC will automatically erase the stored DTC. For other internal faults, the stored DTC is latched forever. On vehicles equipped with the Occupant Classification System (OCS), the ORC communicates with the Occupant Classification Module (OCM) over the CAN data bus. The ORC will internally disable the passenger airbag and seat belt tensioner deployment circuits if the OCM detects that the passenger front seat is unoccupied or that it is occupied by a load that is inappropriate for an airbag deployment. The ORC also provides a control output to the passenger airbag ON/OFF indicator through the passenger airbag indicator driver circuit. The OCM notifies the ORC when it has detected a monitored system fault and stored a DTC in its memory for any ineffective OCS component or circuit, then the ORC sets a DTC and controls the airbag indicator operation accordingly. The ORC receives battery current through two circuits; an ignition switch output (run) circuit and an ignition switch output (run-start) circuit. The ORC receives ground through a ground circuit of the instrument panel wire harness. These connections allow the ORC to be operational whenever the ignition switch is in the START or ON positions. The ORC also contains an energy-storage capacitor. When the ignition switch is in the START or ON positions, this capacitor is continually being charged with enough electrical energy to deploy the supplemental restraint components for up to one second following a battery disconnect or failure. The purpose of the capacitor is to provide backup supplemental restraint system protection in case there is a loss of battery current supply to the ORC during an impact. Two sensors are contained within the ORC, an electronic impact sensor and a safing sensor. The ORC also monitors inputs from two remote front impact sensors located on the back of the right and left vertical members of the radiator support near the front of the vehicle. The electronic impact sensors are accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. On vehicles equipped with optional side airbags, the ORC also monitors inputs from an internal rollover sensor and four additional remote impact sensors located on the left and right inner B-pillars and C-pillars to control deployment of the side airbag units. The safing sensor is an electronic accelerometer sensor within the ORC that provides an additional logic input to the ORC microprocessor. The safing sensor is used to verify the need for a supplemental restraint deployment by detecting impact energy of a lesser magnitude than that of the primary electronic impact sensors, and must exceed a safing threshold in order for the airbags to deploy. Vehicles equipped with optional side airbags, feature a second safing sensor within the ORC to provide confirmation to the ORC microprocessor of side impact forces. This second safing sensor is a bi-directional unit that detects impact forces from either side of the vehicle. Pre-programmed decision algorithms in the ORC microprocessor determine when the deceleration rate as signaled by the impact sensors and the safing sensors indicate an impact that is severe enough to require supplemental restraint system protection and, based upon the severity of the monitored impact, determines the level of front airbag deployment force required for each front seating position. When the programmed conditions are met, the ORC sends the proper electrical signals to deploy the dual multistage front airbags at the programmed force levels, the front seat belt tensioners and, if the vehicle is so equipped, either side airbag unit. For vehicles equipped with the OCS, the passenger front airbag and seat belt tensioner will be deployed by the ORC only if enabled by the OCM messages (passenger airbag ON/OFF indicator OFF) at the time of the impact. To diagnose the ORC or the electronic controls and communication related to ORC operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal Air Bag Control Module: Service and Repair Removal REMOVAL 1. Open hood. 2. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. 3. Remove the floor shifter bezel (1). 4. It is necessary to lift up but not remove on the jute covered panel (1) covering the ORC (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal > Page 361 5. Remove the ORC mounting nuts (2). 6. Disconnect the two ORC connectors (4). 7. Remove ORC (3) from vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal > Page 362 Air Bag Control Module: Service and Repair Installation INSTALLATION NOTE: Make sure to leave the ORC covering panel (1) is in place. Failure to do so may result in false ORC DTC's. The covering prevents the shifter cables from smacking on the top of the ORC and possibly setting a false code. 1. Make sure to lift up on the ORC covering panel to insert the ORC. 2. Connect the two ORC connectors (4) and ensure that the connectors are engaged. 3. Position ORC (arrow pointing forward) on the console floor bracket and mounting studs (1). 4. Install the three ORC retaining nuts (2) and tighten to 9 Nm (79.5 in. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal > Page 363 5. Install floor shifter bezel (1). WARNING: Do not connect the battery negative cable. Personal injury or death may result if the system test is not performed first. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Description and Operation > Description Seat Occupant Classification Module - Air Bag: Description and Operation Description DESCRIPTION The Occupant Classification Module (OCM) (1) is secured to the passenger side outboard front seat track riser. Concealed within a hollow in the center of the molded plastic OCM housing is a microprocessor and the other electronic circuitry of the module. The module housing is sealed to enclose and protect the internal electronic circuitry. The OCM and all of the other components of the Occupant Classification System (OCS) including the passenger side front seat, the seat weight sensors, the passenger or driver seat track position sensor and the seat adjusters, cushion, back, frame, foam, springs, and wiring harness are a factory-calibrated and assembled unit. Any time any one of these components is removed or replaced for any reason, the OCM must be re-calibrated using a diagnostic scan tool, the Occupant Classification Seat Weight special tool 9077, and the Occupant Classification System Verification Test. Refer to the appropriate diagnostic procedures. The OCM cannot be adjusted or repaired and, if damaged or faulty, it must be replaced. The OCM software is flash programmable. A non-calibrated OCM is available for separate service replacement. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Description and Operation > Description > Page 368 Seat Occupant Classification Module - Air Bag: Description and Operation Operation OPERATION The microprocessor in the Occupant Classification Module (OCM) contains the Occupant Classification System (OCS) logic circuits. The OCM uses On-Board Diagnostics (OBD) and can communicate with other electronic modules in the vehicle as well as with the diagnostic scan tool using the Controller Area Network (CAN) data bus. This method of communication is also used for OCS diagnosis and testing through the 16-way Data Link Connector (DLC) located on the driver side lower edge of the instrument panel. The OCM provides voltage to the four seat weight sensors located on each of the four corners of the passenger side front seat, and to the seat track position sensors located on the passenger and driver front seat tracks. The OCM then monitors return inputs from each of the sensors on dedicated hard wired data communication circuits. The seat weight sensor input allows the OCM to determine whether the passenger front seat is occupied and the relative size of the occupant by providing a weight-sensing reference to the load on the seat. The seat track position sensor provides an additional logic input to the OCM microprocessor that allows it to determine the position of the front seat passenger and driver relative to the front airbags. Pre-programmed decision algorithms and OCS calibration allow the OCM microprocessor to determine when passenger airbag protection is appropriate based upon the seat load as signaled by the seat weight sensors. When the programmed conditions are met, the OCM sends the proper electronic occupant classification messages over the CAN data bus to the Occupant Restraint Controller (ORC), and the ORC enables or disables the deployment circuits for the passenger front supplemental restraints. On vehicles so equipped, the ORC also provides a control output for the passenger airbag on/off indicator in the instrument panel based upon the electronic occupant classification messages it receives from the OCM. The OCM also sends electronic driver and passenger seat track position messages to the ORC over the CAN data bus. The ORC uses the seat track position data as an additional logic input for determining the force level with which to deploy the multistage front airbags. The OCM microprocessor continuously monitors all of the OCS electrical circuits and components to determine the system readiness. If the OCM detects a monitored system fault, it sets an active and stored Diagnostic Trouble Code (DTC) and sends the appropriate electronic messages to the ORC over the CAN data bus. Then the ORC sets a DTC and sends messages to control the airbag indicator operation accordingly. An active fault only remains for the duration of the fault, or in some cases for the duration of the current ignition switch cycle, while a stored fault causes a DTC to be stored in memory by the OCM and the ORC. For some DTC's, if a fault does not recur for a number of ignition cycles, the OCM will automatically erase the stored DTC. For other internal faults, the stored DTC is latched forever. The OCM receives battery current on a fused ignition switch output (run-start) circuit through a fuse in the Junction Block (JB). The OCM receives ground through a ground circuit of the body wire harness. These connections allow the OCM to be operational whenever the ignition switch is in the Start or On positions. To diagnose the OCM and all its inputs, outputs and related circuits, use a diagnostic scan tool and the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Service and Repair > Removal Seat Occupant Classification Module - Air Bag: Service and Repair Removal REMOVAL WARNING: The replacement Occupant Classification Module (OCM) is a non-calibrated unit when first installed. The OCM and all of the other components of the Occupant Classification System (OCS) including the passenger front seat, the seat weight sensors, the passenger or driver seat track position sensor and the seat adjusters, cushion, back, frame, foam, springs, and wiring harness are a factory-calibrated and assembled unit. Any time any one of these components is removed or replaced for any reason, the OCM must be re-calibrated using a diagnostic scan tool, the Occupant Classification Seat Weight special tool 9077, and the Occupant Classification System Verification Test. Refer to the appropriate diagnostic procedures. 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. 2. Reach under the front edge of the passenger side front seat cushion to access and remove the two screws that secure the Occupant Classification Module (OCM) (3) to the underside of the passenger front seat cushion pan. 3. Pull the OCM down far enough to access the module wiring connections (4). 4. Disconnect the two electrical connectors (4) from the OCM (3). 5. Remove the OCM (3) from under the passenger front seat. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Service and Repair > Removal > Page 371 Seat Occupant Classification Module - Air Bag: Service and Repair Installation INSTALLATION WARNING: A non-calibrated Occupant Classification Module (OCM) is available for separate service replacement. The OCM and all of the other components of the Occupant Classification System (OCS) including the passenger side front seat, the seat weight sensors, the passenger or driver seat track position sensor and the seat adjusters, cushion, back, frame, foam, springs, and wiring harness are a factory-calibrated and assembled unit. Any time any one of these components is removed or replaced for any reason, the OCM must be re-calibrated using a diagnostic scan tool, the Occupant Classification Seat Weight special tool 9077, and the Occupant Classification System Verification Test. Refer to the appropriate diagnostic procedures. 1. Position the Occupant Classification Module (OCM) (3) under the passenger front seat cushion. 2. Connect the two electrical connectors (4) to the OCM (3). 3. Carefully position the OCM to the seat cushion pan. 4. Install the two screws that secure the OCM to the seat cushion pan. WARNING: Do not connect the battery negative cable. Personal injury or death may result if the system test is not performed first. WARNING: Following successful completion of the Airbag System verification test procedure, perform the Occupant Classification System Verification Test using a diagnostic scan tool and the Occupant Classification Seat Weight special tool 9077. Refer to the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Description and Operation > Description Steering Column Control Module: Description and Operation Description DESCRIPTION This vehicle is equipped with a Steering Column Control Module (SCCM) The SCCM is secured near the top of the steering column below the steering wheel and is completely concealed beneath the steering column shrouds. It is installed as a modular unit that supports the left (lighting) multi-function switch (1) and right (wiper) multi-function switch (6). The controls for each of these switches extend through appropriate clearance holes provided in the steering column shrouds. The microprocessor-based Steering Control Module (SCM) (2) utilizes integrated circuitry and information carried on the Controller Area Network (CAN) data bus along with several hard wired analog and multiplexed inputs to monitor both the right and left multi-function switches. The SCCM uses a Local Interconnect Network (LIN) data bus for exterior lighting and wiper functions. The LIN data is sent to the Cab Compartment Node (CCN) and the CCN then sends it out on the CAN data bus. The SCCM is available for service replacement as a unit or each individual component: - Clockspring (with integral Steering Angle Sensor if equipped) - Left Multi-Function Switch - Right Multi-Function Switch Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Description and Operation > Description > Page 378 Steering Column Control Module: Description and Operation Operation OPERATION The Steering Control Module (SCM) communicates over the Local Interconnect Network (LIN) data bus with other electronic modules in the vehicle and/or a diagnostic scan tool. The horn switch circuits pass through the clockspring to the Cab Compartment Node (CCN) and the CCN sends a CAN message to the Totally Integrated Power Module (TIPM) to control the horn. The CCN stores Diagnostic Trouble Codes (DTC's) for the SCM. The right (wiper) multi-function switch has several inputs to the CCN. The SCM is connected to a fused B(+) circuit and receives a path to ground at all times. These connections allow it to remain functional regardless of the ignition switch position. The driver airbag squib circuits of the clockspring, the horn, and the speed control switch circuits pass through the SCM, but the SCM does not monitor, and has no control outputs related to these circuits. Any other input to the SCM that would cause a vehicle system to function but does not require that the ignition switch be in the On position, such as turning on the lights or sounding the horn, prompts the SCM to wake up and transmit on the CAN data bus. The most reliable, efficient, and accurate means to diagnose the SCM, the CAN data bus, the hard wired inputs or the electronic communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. The integral SCM is not available for separate service replacement. If found inoperative or defective, the entire left (lighting) multi-function switch must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Service and Repair > Removal Steering Column Control Module: Service and Repair Removal REMOVAL SCCM 1. Place the front road wheels in the STRAIGHT-AHEAD position. 2. Open hood. 3. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. 4. Remove steering wheel. 5. Remove upper and lower steering column shrouds to gain access to the Steering Column Control Module (SCCM). 6. Lock the clockspring rotor in the center position as follows: Insert a grenade pin through the hole in the rotor at the 10 o'clock position. 7. Remove the three screws (1) to the Steering Column Control Module (SCCM) (3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Service and Repair > Removal > Page 381 8. Disconnect the electrical connectors (2) between the SCCM (1) and the instrument panel wiring harness at the base of the SCCM and remove from column. NOTE: If only removing the SCCM from column, there is no need to continue to next step. DISASSEMBLY 1. Remove the left multi-function switch stalk retaining screw (2). 2. Pull the left stalk out of the SCCM. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Service and Repair > Removal > Page 382 3. Disconnect the left stalk electrical connector. 4. Separate the left switch from the SCCM. 5. Remove the one right multi-function switch retaining screw. 6. Pull right switch out of SCCM. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Service and Repair > Removal > Page 383 7. Disconnect the right switch electrical connector. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Service and Repair > Removal > Page 384 Steering Column Control Module: Service and Repair Installation INSTALLATION NOTE: If SCCM is already assembled and needs to be installed, bypass ASSEMBLY and proceed with SCCM STEP 1. ASSEMBLY 1. Connect the right stalk electrical connector. 2. Slide the right stalk into the groove and install the one retaining screw. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Service and Repair > Removal > Page 385 3. Connect the left stalk switch electrical connector. 4. Install the left stalk switch retaining screw. SCCM Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Service and Repair > Removal > Page 386 1. Position the SCCM (3) over the steering column shaft (2). 2. Install the three screws (1). 3. Connect the electrical connectors (2) to the instrument panel harness, ensure wiring is properly routed. Then check that the connectors, locking tabs are properly engaged. 4. Install steering column shrouds. Be sure all wires are inside of shrouds. 5. Install steering wheel ensuring the flats on hub align with the clockspring. Pull the airbag leads through the larger slot. Ensure leads do not get pinched under the steering wheel. NOTE: There is a small wire harness in the steering wheel and it contains the horn circuits and speed control circuits. 6. Connect the speed control and horn wire connector into the clockspring. 7. Pull the grenade pin out of the clockspring. 8. Install the driver airbag. WARNING: Do not connect the battery negative cable. Personal injury or death may result if the system test is not performed first. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations Steering Control Module: Locations Component ID: 162 Component : MODULE-STEERING CONTROL Connector: Name : MODULE-STEERING CONTROL C1 Color : WHITE # of pins : 4 Pin Description Circuit 1 GROUND Z937 20BK/YL Pin Description Circuit 1 GROUND Z936 20BK/LB 2 FUSED B(+) (I.O.D.) A411 20RD/LG 3 LIN BUS D506 20WT/DG 4 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY Component Location - 28 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 390 Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 391 Connector: Name : MODULE-STEERING CONTROL C2 Color : WHITE # of pins : 6 Pin Description Circuit 1 RADIO CONTROL MUX X20 20GY/WT 2 RADIO CONTROL RETURN Y13 20DG/RD 3 HORN SWITCH SENSE X3 20DG/VT 4 S/C SIGNAL 2 V72 20OR/VT 5 S/C SWITCH GROUND V937 20VT/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 392 6 S/C SIGNAL 1 V71 20VT/OR Component Location - 28 Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 393 Connector: Name : MODULE-STEERING CONTROL C4 Color : WHITE # of pins : 4 Pin Description Circuit 1 DRIVER SQUIB 2 LINE 1 R63 18LG/BK 2 DRIVER SQUIB 2 LINE 2 R61 18LG/VT 3 DRIVER SQUIB 1 LINE 1 R45 18LG/RD 4 DRIVER SQUIB 1 LINE 2 R43 18LG/BR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 394 Component Location - 28 Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 395 Connector: Name : MODULE-STEERING CONTROL C5 Color : WHITE # of pins : 6 Pin Description Circuit 1 RADIO CONTROL MUX X20 20GY Pin Description Circuit 1 RADIO CONTROL MUX X20 20GY 2 RADIO CONTROL RETURN Y13 20BK Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 396 2 RADIO CONTROL RETURN Y13 20BK 3 HORN SWITCH SENSE X3 20DB 4 S/C SIGNAL 2 V72 20PK 5 S/C SIGNAL 1 V71 20VT 6 S/C SWITCH GROUND V937 20YL Component Location - 28 Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 397 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 398 Steering Control Module: Diagrams Component ID: 162 Component : MODULE-STEERING CONTROL Connector: Name : MODULE-STEERING CONTROL C1 Color : WHITE # of pins : 4 Pin Description Circuit 1 GROUND Z937 20BK/YL Pin Description Circuit 1 GROUND Z936 20BK/LB 2 FUSED B(+) (I.O.D.) A411 20RD/LG 3 LIN BUS D506 20WT/DG 4 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY Component Location - 28 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 399 Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 400 Connector: Name : MODULE-STEERING CONTROL C2 Color : WHITE # of pins : 6 Pin Description Circuit 1 RADIO CONTROL MUX X20 20GY/WT 2 RADIO CONTROL RETURN Y13 20DG/RD 3 HORN SWITCH SENSE X3 20DG/VT 4 S/C SIGNAL 2 V72 20OR/VT 5 S/C SWITCH GROUND V937 20VT/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 401 6 S/C SIGNAL 1 V71 20VT/OR Component Location - 28 Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 402 Connector: Name : MODULE-STEERING CONTROL C4 Color : WHITE # of pins : 4 Pin Description Circuit 1 DRIVER SQUIB 2 LINE 1 R63 18LG/BK 2 DRIVER SQUIB 2 LINE 2 R61 18LG/VT 3 DRIVER SQUIB 1 LINE 1 R45 18LG/RD 4 DRIVER SQUIB 1 LINE 2 R43 18LG/BR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 403 Component Location - 28 Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 404 Connector: Name : MODULE-STEERING CONTROL C5 Color : WHITE # of pins : 6 Pin Description Circuit 1 RADIO CONTROL MUX X20 20GY Pin Description Circuit 1 RADIO CONTROL MUX X20 20GY 2 RADIO CONTROL RETURN Y13 20BK Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 405 2 RADIO CONTROL RETURN Y13 20BK 3 HORN SWITCH SENSE X3 20DB 4 S/C SIGNAL 2 V72 20PK 5 S/C SIGNAL 1 V71 20VT 6 S/C SWITCH GROUND V937 20YL Component Location - 28 Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 406 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Description Steering Mounted Controls Communication Module: Description and Operation Description DESCRIPTION This vehicle is equipped with a Steering Column Control Module (SCCM) The SCCM is secured near the top of the steering column below the steering wheel and is completely concealed beneath the steering column shrouds. It is installed as a modular unit that supports the left (lighting) multi-function switch (1) and right (wiper) multi-function switch (6). The controls for each of these switches extend through appropriate clearance holes provided in the steering column shrouds. The microprocessor-based Steering Control Module (SCM) (2) utilizes integrated circuitry and information carried on the Controller Area Network (CAN) data bus along with several hard wired analog and multiplexed inputs to monitor both the right and left multi-function switches. The SCCM uses a Local Interconnect Network (LIN) data bus for exterior lighting and wiper functions. The LIN data is sent to the Cab Compartment Node (CCN) and the CCN then sends it out on the CAN data bus. The SCCM is available for service replacement as a unit or each individual component: - Clockspring (with integral Steering Angle Sensor if equipped) - Left Multi-Function Switch - Right Multi-Function Switch Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Description > Page 411 Steering Mounted Controls Communication Module: Description and Operation Operation OPERATION The Steering Control Module (SCM) communicates over the Local Interconnect Network (LIN) data bus with other electronic modules in the vehicle and/or a diagnostic scan tool. The horn switch circuits pass through the clockspring to the Cab Compartment Node (CCN) and the CCN sends a CAN message to the Totally Integrated Power Module (TIPM) to control the horn. The CCN stores Diagnostic Trouble Codes (DTC's) for the SCM. The right (wiper) multi-function switch has several inputs to the CCN. The SCM is connected to a fused B(+) circuit and receives a path to ground at all times. These connections allow it to remain functional regardless of the ignition switch position. The driver airbag squib circuits of the clockspring, the horn, and the speed control switch circuits pass through the SCM, but the SCM does not monitor, and has no control outputs related to these circuits. Any other input to the SCM that would cause a vehicle system to function but does not require that the ignition switch be in the On position, such as turning on the lights or sounding the horn, prompts the SCM to wake up and transmit on the CAN data bus. The most reliable, efficient, and accurate means to diagnose the SCM, the CAN data bus, the hard wired inputs or the electronic communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. The integral SCM is not available for separate service replacement. If found inoperative or defective, the entire left (lighting) multi-function switch must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front Tire Pressure Monitor Receiver / Transponder: Locations Transponder-Tire Pressure-Left Front Component ID: 361 Component : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Connector: Name : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Color : YELLOW # of pins : 6 Qualifier : (TIRE PRESSURE MONITOR) Pin Description Circuit 1 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 GROUND Z904 20BK/OR 4 GROUND Z904 20BK/OR 5-6-- Component Location - 13 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 417 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 418 Tire Pressure Monitor Receiver / Transponder: Locations Transponder-Tire Pressure-Left Rear Component ID: 362 Component : TRANSPONDER-TIRE PRESSURE-LEFT REAR Connector: Name : TRANSPONDER-TIRE PRESSURE-LEFT REAR Color : BLACK # of pins : 6 Qualifier : (TIRE PRESSURE MONITOR) Pin Description Circuit 1 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 GROUND Z904 20BK/OR 4-5-6-- Component Location - 58 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 419 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 420 Tire Pressure Monitor Receiver / Transponder: Locations Transponder-Tire Pressure-Right Rear Component ID: 363 Component : TRANSPONDER-TIRE PRESSURE-RIGHT REAR Connector: Name : TRANSPONDER-TIRE PRESSURE-RIGHT REAR Color : BLACK # of pins : 6 Qualifier : (TIRE PRESSURE MONITOR) Pin Description Circuit 1 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 GROUND Z965 20BK/GY 4-5-6 GROUND Z965 20BK/GY Component Location - 59 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 421 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front Tire Pressure Monitor Receiver / Transponder: Diagrams Transponder-Tire Pressure-Left Front Component ID: 361 Component : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Connector: Name : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Color : YELLOW # of pins : 6 Qualifier : (TIRE PRESSURE MONITOR) Pin Description Circuit 1 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 GROUND Z904 20BK/OR 4 GROUND Z904 20BK/OR 5-6-- Component Location - 13 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 424 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 425 Tire Pressure Monitor Receiver / Transponder: Diagrams Transponder-Tire Pressure-Left Rear Component ID: 362 Component : TRANSPONDER-TIRE PRESSURE-LEFT REAR Connector: Name : TRANSPONDER-TIRE PRESSURE-LEFT REAR Color : BLACK # of pins : 6 Qualifier : (TIRE PRESSURE MONITOR) Pin Description Circuit 1 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 GROUND Z904 20BK/OR 4-5-6-- Component Location - 58 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 426 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 427 Tire Pressure Monitor Receiver / Transponder: Diagrams Transponder-Tire Pressure-Right Rear Component ID: 363 Component : TRANSPONDER-TIRE PRESSURE-RIGHT REAR Connector: Name : TRANSPONDER-TIRE PRESSURE-RIGHT REAR Color : BLACK # of pins : 6 Qualifier : (TIRE PRESSURE MONITOR) Pin Description Circuit 1 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 GROUND Z965 20BK/GY 4-5-6 GROUND Z965 20BK/GY Component Location - 59 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 428 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Description Tire Pressure Monitor Receiver / Transponder: Description and Operation Description DESCRIPTION A transponder, sometimes referred to as a trigger module, is located in three of the four wheel wells (behind the wheelhouse splash shields) of a vehicle equipped with Premium TPM. These transponders are used to provide the Wireless Control Module (WCM), commonly referred to as the Sentry Key Remote Entry Module (SKREEM), with the location of the tire pressure sensors on the vehicle. A fourth transponder is not necessary in the remaining wheel well due to the process-of-elimination theory. Once the system knows the location of the first three sensors it assumes the location of the fourth tire pressure sensor. On this vehicle, there is a transponder located in the left front, left rear, and right rear wheelhouse. There is not a transponder located in the right front wheelhouse. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Description > Page 431 Tire Pressure Monitor Receiver / Transponder: Description and Operation Operation OPERATION On vehicles equipped with the premium TPM system, the Wireless Control Module (WCM), commonly referred to as the Sentry Key Remote Entry Module (SKREEM), uses transponders (trigger modules) located in three of the four wheel wells on the vehicle to provide it with the location of the tire pressure sensors on the vehicle. Like the base system, the WCM receives RF signals from all four rotating wheel speed sensors. When the WCM needs to know which sensor is located at a particular location on the vehicle, it directs the transponder at that location to send out a low frequency signal to excite the nearby sensor. The WCM then receives that excited signal and knows where that sensor is located. This auto-locating process only happens in the first 10 minutes of any WCM cycle while traveling at speeds above 20 mph (32 km/h). (The auto-locating process will start again only if the vehicle has been shut off for approximately 20 minutes or longer). Once the WCM has performed this to the three locations that have transponders, it uses the process-of-elimination theory to know that the fourth sensor ID signal is coming from. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Removal Tire Pressure Monitor Receiver / Transponder: Service and Repair Removal Front FRONT 1. Remove the wheelhouse splash shield at the transponder requiring service. 2. Disconnect the wiring harness connector (2) at the transponder (1). 3. Remove the mounting nuts (3), then remove the transponder (1). Rear REAR 1. Remove the wheelhouse splash shield at the transponder requiring service. 2. Disconnect the wiring harness connector (3) at the transponder (1). 3. Remove the mounting nuts (2), then remove the transponder (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Removal > Page 434 Tire Pressure Monitor Receiver / Transponder: Service and Repair Installation Front FRONT 1. Position the transponder (1) and install the mounting nuts (3). 2. Connect the wiring harness connector (2) to the transponder (1). 3. Install the wheelhouse splash shield and all components removed to access it. 4. Perform the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests Rear REAR 1. Position the transponder (1) and install the mounting nuts (2). 2. Connect the wiring harness connector (3) to the transponder (1). 3. Install the rear wheelhouse splash shield and all components removed to access it. 4. Perform the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor Control Module: Technical Service Bulletins Engine Controls - MIL On/DTC P0116/ECT Sensor NUMBER: 18-039-06 GROUP: Vehicle Performance DATE: December 6, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES FOR StarSCAN. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 7.02 SP2 OR HIGHER FOR THIS BULLETIN. SUBJECT: Flash: MIL Illumination DTC P0116 - Engine Coolant Temperature Sensor Performance OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) and the Transmission Control Module (1CM) with new software. CAUTION: VEHICLES EQUIPPED WITH A CVT TRANSMISSION MUST HAVE THE TRANSMISSION CONTROL MODULE (TCM) CHECKED FOR THE LATEST SOFTWARE LEVEL WHENEVER THE PCM SOFTWARE IS UPGRADED. IF NEWER TCM SOFTWARE IS AVAILABLE, IT MUST BE INSTALLED. MODELS: 2007 (PM) Caliber 2007 (MK49) Compass NOTE: This bulletin applies to PM/MK models equipped with a 1.8L, 2.0L or 2.4L gasoline engine (Sales Code EBA, ECN or ED3) and block heater (Sales Code NHK) built before November 20, 2006 (MDH 1120XX). NOTE: If an aftermarket or MOPAR accessory block heater is installed, the same conditions may apply. SYMPTOM/CONDITION: Some customers may experience MIL illumination after using the block heater. No other symptoms will be experienced. The technician may find the following DTC's: ^ P0116 - ENGINE COOLANT TEMPERATURE SENSOR PERFORMANCE DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If MIL illumination with DTC P0116 is present, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 441 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING **STEP 5n and/or 8h**. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 7.02 SP2 software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. PM/MK Models equipped with a CVT must have the TCM reprogrammed as follows: 6. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. 7. Is the TCM part number recorded in step 6e above, the same as the new p/n shown on the "Flash File List" screen? a. Yes >> No further action is necessary. Proceed to Step 9. b. No >> the TCM will require flash reprogramming, proceed to Step 8. 8. Flash reprogram the TCM as follows: a. From the "Flash File List" screen, select "Download to Scantool". b. Select "Close" after the download is complete, then select "Back". c. Highlight the listed calibration. d. Select "Update Controller". Follow on screen instructions. e. When the update is complete, select "OK". f. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. g. Turn the ignition switch to the OFF position for no less than 15 seconds. h. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 442 CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the TCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. ** NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 9. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 Control Module: Customer Interest A/T - MIL ON Possible DTC P2004 NUMBER: 18-032-07 GROUP: Vehicle Performance DATE: May 16, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 7.04 SPI OR HIGHER FOR THIS BULLETIN. SUBJECT: Flash: MIL Illumination with DIG P2004 OVERVIEW: This bulletin involves selectively erasing and reprogramming the GPEC Powertrain Control Module (PCM) with new software and replacing the intake manifold as required. CAUTION: VEHICLES EQUIPPED WITH A CVT TRANSMISSION MUST HAVE THE TRANSMISSION CONTROL MODULE (TCM) CHECKED FOR THE LATEST SOFTWARE LEVEL WHENEVER THE PCM SOFTWARE IS UPGRADED. IF NEWER TCM SOFTWARE IS AVAILABLE, IT MUST BE INSTALLED. MODELS: 2007-2008 (JS) Avenger 2007 (JS) Sebring 2008 (J527) Sebring Convertible 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to models equipped with a 1.8L, 2.0L or 2.4L gasoline engine (Sales Code EBA, ECN or ED3) as follows: Flash portion applies to PM/MK models built through April 21, 2007 (MDH 0421 XX) and JS models built through May 15, 2007 (0515XX). The Intake Manifold Replacement portion applies to models built through March 22, 2007 (MDHO322XX). SYMPTOM/CONDITION: Some customers may experience MIL Illumination with no other symptoms. The condition may occur intermittently. Further investigation by the technician may find DTC P2004 - Intake Manifold Runner Control Stuck Open as the cause for MIL Illumination. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine Systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Perform the standard diagnostic procedures for DIG P2004. If the diagnostics do not lead to the failure, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 452 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and/or 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 7.04 SPI software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service> StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options d. Select "ECU Flash e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 453 j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. m. Turn the ignition switch to the OFF position for no less than 15 seconds. n. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING 5n OR 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. PM/MK Models equipped with a CVT must have the TCM reprogrammed as follows: 6. Using the StarSCAN(R) at the "Home screen": a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. 7. Is the TCM part number recorded in step 6e above, the same as the new pin shown on the "Flash File List" screen? a. Yes > No further action is necessary. Proceed to Step 9. b. No > the TCM will require flash reprogramming, proceed to Step 8. 8. Flash reprogram the TCM as follows: a. From the "Flash File List screen, select "Download to Scantool". b. Select "Close" after the download is complete, then select "Back". c. Highlight the listed calibration. d. Select "Update Controller". Follow on screen instructions. e. When the update is complete, select "OK". f. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. g. Turn the ignition switch to the OFF position for no less than 15 seconds. h. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP Sn and 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the TCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list.** Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 454 NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig.1). 1. Vehicles built through March 22, 2007 will require a new Intake Manifold pn 04884495AF. Following the procedures listed in DealerCONNECT > TechCONNECT replace the intake manifold. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B Technical Service Bulletin # 18-019-06 Date: 060607 A/T Controls - MIL ON/DTC's P0602/P167A or P161B NUMBER: 18-019-06 GROUP: Vehicle Performance DATE: June 7, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: Flash: MIL Illumination - DTC's P0602, P167A, or P161B OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (TCM) with new software and the Powertrain Control Module (PCM) with new software. WARNING: BOTH CONTROLLERS (TCM AND PCM) MUST BE REPROGRAMMED. THIS UPDATE MUST BE COMPLETED AS A COORDINATED CHANGE. IF THE PCM IS NOT UPDATED, MIL ILLUMINATION CAN OCCUR AND DTC U1424 (IMPLAUSIBLE ENGINE TORQUE MESSAGE RECEIVED) WILL BE RECORDED IN THE TCM. MODELS: 2007 (PM) Caliber NOTE: This bulletin applies to vehicles equipped with a Continuously Variable Transmission (CVT), (sales code DAV), built on or before June 1, 2006 (MDH 0601XX). SYMPTOM/CONDITION: The customer may experience Malfunction Indicator Lamp (MIL) illumination. The technician may find the following Diagnostic Trouble Codes (DTC's) in the TCM: ^ P0602-Control Module Programming Error/Not Programmed ^ P167A-Calibration Mismatch ^ P161B-Battery Disconnect / TCM Internal DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes MIL Illumination and the technician finds any of the DTC's listed above, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B > Page 459 SPECIAL TOOLS / EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. TCM - Repair Procedure - Using the Internet to Retrieve the Flash File NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 6.06 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old TCM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B > Page 460 b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". I. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. NOTE: Due to the TCM/PCM programming procedure, a DTC may be set in other modules (BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTC's". Press "Clear All Stored DTC's" if there are any DTC's shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 6. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). PCM Repair Procedure - Using the Internet to Retrieve the Flash File CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 6.06 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B > Page 461 StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the PCM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. m. Turn the ignition switch to the OFF position for no less than 15 seconds. n. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 6. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 Control Module: All Technical Service Bulletins A/T - MIL ON Possible DTC P2004 NUMBER: 18-032-07 GROUP: Vehicle Performance DATE: May 16, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 7.04 SPI OR HIGHER FOR THIS BULLETIN. SUBJECT: Flash: MIL Illumination with DIG P2004 OVERVIEW: This bulletin involves selectively erasing and reprogramming the GPEC Powertrain Control Module (PCM) with new software and replacing the intake manifold as required. CAUTION: VEHICLES EQUIPPED WITH A CVT TRANSMISSION MUST HAVE THE TRANSMISSION CONTROL MODULE (TCM) CHECKED FOR THE LATEST SOFTWARE LEVEL WHENEVER THE PCM SOFTWARE IS UPGRADED. IF NEWER TCM SOFTWARE IS AVAILABLE, IT MUST BE INSTALLED. MODELS: 2007-2008 (JS) Avenger 2007 (JS) Sebring 2008 (J527) Sebring Convertible 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to models equipped with a 1.8L, 2.0L or 2.4L gasoline engine (Sales Code EBA, ECN or ED3) as follows: Flash portion applies to PM/MK models built through April 21, 2007 (MDH 0421 XX) and JS models built through May 15, 2007 (0515XX). The Intake Manifold Replacement portion applies to models built through March 22, 2007 (MDHO322XX). SYMPTOM/CONDITION: Some customers may experience MIL Illumination with no other symptoms. The condition may occur intermittently. Further investigation by the technician may find DTC P2004 - Intake Manifold Runner Control Stuck Open as the cause for MIL Illumination. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine Systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Perform the standard diagnostic procedures for DIG P2004. If the diagnostics do not lead to the failure, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 467 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and/or 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 7.04 SPI software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service> StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options d. Select "ECU Flash e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 468 j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. m. Turn the ignition switch to the OFF position for no less than 15 seconds. n. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING 5n OR 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. PM/MK Models equipped with a CVT must have the TCM reprogrammed as follows: 6. Using the StarSCAN(R) at the "Home screen": a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. 7. Is the TCM part number recorded in step 6e above, the same as the new pin shown on the "Flash File List" screen? a. Yes > No further action is necessary. Proceed to Step 9. b. No > the TCM will require flash reprogramming, proceed to Step 8. 8. Flash reprogram the TCM as follows: a. From the "Flash File List screen, select "Download to Scantool". b. Select "Close" after the download is complete, then select "Back". c. Highlight the listed calibration. d. Select "Update Controller". Follow on screen instructions. e. When the update is complete, select "OK". f. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. g. Turn the ignition switch to the OFF position for no less than 15 seconds. h. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP Sn and 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the TCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list.** Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 469 NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig.1). 1. Vehicles built through March 22, 2007 will require a new Intake Manifold pn 04884495AF. Following the procedures listed in DealerCONNECT > TechCONNECT replace the intake manifold. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B Technical Service Bulletin # 18-019-06 Date: 060607 A/T Controls - MIL ON/DTC's P0602/P167A or P161B NUMBER: 18-019-06 GROUP: Vehicle Performance DATE: June 7, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: Flash: MIL Illumination - DTC's P0602, P167A, or P161B OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (TCM) with new software and the Powertrain Control Module (PCM) with new software. WARNING: BOTH CONTROLLERS (TCM AND PCM) MUST BE REPROGRAMMED. THIS UPDATE MUST BE COMPLETED AS A COORDINATED CHANGE. IF THE PCM IS NOT UPDATED, MIL ILLUMINATION CAN OCCUR AND DTC U1424 (IMPLAUSIBLE ENGINE TORQUE MESSAGE RECEIVED) WILL BE RECORDED IN THE TCM. MODELS: 2007 (PM) Caliber NOTE: This bulletin applies to vehicles equipped with a Continuously Variable Transmission (CVT), (sales code DAV), built on or before June 1, 2006 (MDH 0601XX). SYMPTOM/CONDITION: The customer may experience Malfunction Indicator Lamp (MIL) illumination. The technician may find the following Diagnostic Trouble Codes (DTC's) in the TCM: ^ P0602-Control Module Programming Error/Not Programmed ^ P167A-Calibration Mismatch ^ P161B-Battery Disconnect / TCM Internal DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes MIL Illumination and the technician finds any of the DTC's listed above, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B > Page 474 SPECIAL TOOLS / EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. TCM - Repair Procedure - Using the Internet to Retrieve the Flash File NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 6.06 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old TCM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B > Page 475 b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". I. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. NOTE: Due to the TCM/PCM programming procedure, a DTC may be set in other modules (BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTC's". Press "Clear All Stored DTC's" if there are any DTC's shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 6. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). PCM Repair Procedure - Using the Internet to Retrieve the Flash File CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 6.06 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B > Page 476 StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the PCM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. m. Turn the ignition switch to the OFF position for no less than 15 seconds. n. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 6. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > System Information > Technical Service Bulletins > Customer Interest for Relays and Modules - Wiper and Washer Systems: > 08-027-06 > Jun > 06 > Wipers/Washers - Rear Wiper Inop./DTC's B231B & B2215 Relays and Modules - Wiper and Washer Systems: Customer Interest Wipers/Washers - Rear Wiper Inop./DTC's B231B & B2215 NUMBER: 08-027-06 GROUP: Electrical DATE: June 5, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: Flash - Rear Wiper Stops Operating with Diagnostic Trouble Codes B231B And B2215 OVERVIEW: This bulletin involves Flash Reprogramming the Totally Integrated Power Module (11PM) with updated software. MODELS: 2006 (PT) PT Cruiser 2007 (PM) Caliber NOTE: This bulletin applies to PM vehicles built before May 27, 2006 (MDH 0527XX) and all PT vehicles built before June 2, 2006 (MDH 0602XX) SYMPTOM/CONDITION: The rear wiper may stop operating. Upon further investigation the technician may find that the following Diagnostic Trouble Codes (DTC's) are present:: A. B2215 - FCM Internal B. B231B - Rear Wiper Motor Control Circuit Low DIAGNOSIS: 1. Connect the StarSCAN(R) to the vehicle. 2. Turn the ignition on. 3. With the Scan Tool, clear all TIPM DTC's. 4. Turn the Rear Windshield Wipers on. 5. Does the rear wiper operate? 6. Yes >> Perform the Repair Procedure. 7. No >> This bulletin does not apply, additional diagnosis is required. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > System Information > Technical Service Bulletins > Customer Interest for Relays and Modules - Wiper and Washer Systems: > 08-027-06 > Jun > 06 > Wipers/Washers - Rear Wiper Inop./DTC's B231B & B2215 > Page 485 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 6.06 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old TIPM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the appropriate ECU in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash ECU" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Highlight the listed calibration. h. Select "Download to Scantool". i. Select "Close" after the download is complete, then select "Back". j. Highlight the listed calibration. k. Select "Update Controller". Follow on screen instructions. l. When the update is complete, select "OK". Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > System Information > Technical Service Bulletins > Customer Interest for Relays and Modules - Wiper and Washer Systems: > 08-027-06 > Jun > 06 > Wipers/Washers - Rear Wiper Inop./DTC's B231B & B2215 > Page 486 m. Verify the part number at the top of the "Flash ECU" screen has updated to the new part number. NOTE: Due to the TIPM programming procedure, a DTC may be set in other modules (PCM, TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > System Information > Technical Service Bulletins > All Technical Service Bulletins for Relays and Modules - Wiper and Washer Systems: > 08-027-06 > Jun > 06 > Wipers/Washers - Rear Wiper Inop./DTC's B231B & B2215 Relays and Modules - Wiper and Washer Systems: All Technical Service Bulletins Wipers/Washers - Rear Wiper Inop./DTC's B231B & B2215 NUMBER: 08-027-06 GROUP: Electrical DATE: June 5, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: Flash - Rear Wiper Stops Operating with Diagnostic Trouble Codes B231B And B2215 OVERVIEW: This bulletin involves Flash Reprogramming the Totally Integrated Power Module (11PM) with updated software. MODELS: 2006 (PT) PT Cruiser 2007 (PM) Caliber NOTE: This bulletin applies to PM vehicles built before May 27, 2006 (MDH 0527XX) and all PT vehicles built before June 2, 2006 (MDH 0602XX) SYMPTOM/CONDITION: The rear wiper may stop operating. Upon further investigation the technician may find that the following Diagnostic Trouble Codes (DTC's) are present:: A. B2215 - FCM Internal B. B231B - Rear Wiper Motor Control Circuit Low DIAGNOSIS: 1. Connect the StarSCAN(R) to the vehicle. 2. Turn the ignition on. 3. With the Scan Tool, clear all TIPM DTC's. 4. Turn the Rear Windshield Wipers on. 5. Does the rear wiper operate? 6. Yes >> Perform the Repair Procedure. 7. No >> This bulletin does not apply, additional diagnosis is required. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > System Information > Technical Service Bulletins > All Technical Service Bulletins for Relays and Modules - Wiper and Washer Systems: > 08-027-06 > Jun > 06 > Wipers/Washers - Rear Wiper Inop./DTC's B231B & B2215 > Page 492 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 6.06 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old TIPM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the appropriate ECU in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash ECU" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Highlight the listed calibration. h. Select "Download to Scantool". i. Select "Close" after the download is complete, then select "Back". j. Highlight the listed calibration. k. Select "Update Controller". Follow on screen instructions. l. When the update is complete, select "OK". Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > System Information > Technical Service Bulletins > All Technical Service Bulletins for Relays and Modules - Wiper and Washer Systems: > 08-027-06 > Jun > 06 > Wipers/Washers - Rear Wiper Inop./DTC's B231B & B2215 > Page 493 m. Verify the part number at the top of the "Flash ECU" screen has updated to the new part number. NOTE: Due to the TIPM programming procedure, a DTC may be set in other modules (PCM, TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > System Information > Technical Service Bulletins > All Technical Service Bulletins for Relays and Modules - Wiper and Washer Systems: > Page 494 Relays and Modules - Wiper and Washer Systems: By Symptom Technical Service Bulletin # 08-027-06 Date: 060605 Wipers/Washers - Rear Wiper Inop./DTC's B231B & B2215 NUMBER: 08-027-06 GROUP: Electrical DATE: June 5, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: Flash - Rear Wiper Stops Operating with Diagnostic Trouble Codes B231B And B2215 OVERVIEW: This bulletin involves Flash Reprogramming the Totally Integrated Power Module (11PM) with updated software. MODELS: 2006 (PT) PT Cruiser 2007 (PM) Caliber NOTE: This bulletin applies to PM vehicles built before May 27, 2006 (MDH 0527XX) and all PT vehicles built before June 2, 2006 (MDH 0602XX) SYMPTOM/CONDITION: The rear wiper may stop operating. Upon further investigation the technician may find that the following Diagnostic Trouble Codes (DTC's) are present:: A. B2215 - FCM Internal B. B231B - Rear Wiper Motor Control Circuit Low DIAGNOSIS: 1. Connect the StarSCAN(R) to the vehicle. 2. Turn the ignition on. 3. With the Scan Tool, clear all TIPM DTC's. 4. Turn the Rear Windshield Wipers on. 5. Does the rear wiper operate? 6. Yes >> Perform the Repair Procedure. 7. No >> This bulletin does not apply, additional diagnosis is required. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > System Information > Technical Service Bulletins > All Technical Service Bulletins for Relays and Modules - Wiper and Washer Systems: > Page 495 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 6.06 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old TIPM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the appropriate ECU in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash ECU" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Highlight the listed calibration. h. Select "Download to Scantool". i. Select "Close" after the download is complete, then select "Back". j. Highlight the listed calibration. k. Select "Update Controller". Follow on screen instructions. l. When the update is complete, select "OK". Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > System Information > Technical Service Bulletins > All Technical Service Bulletins for Relays and Modules - Wiper and Washer Systems: > Page 496 m. Verify the part number at the top of the "Flash ECU" screen has updated to the new part number. NOTE: Due to the TIPM programming procedure, a DTC may be set in other modules (PCM, TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 08-027-06 Date: 060605 Wipers/Washers - Rear Wiper Inop./DTC's B231B & B2215 NUMBER: 08-027-06 GROUP: Electrical DATE: June 5, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: Flash - Rear Wiper Stops Operating with Diagnostic Trouble Codes B231B And B2215 OVERVIEW: This bulletin involves Flash Reprogramming the Totally Integrated Power Module (11PM) with updated software. MODELS: 2006 (PT) PT Cruiser 2007 (PM) Caliber NOTE: This bulletin applies to PM vehicles built before May 27, 2006 (MDH 0527XX) and all PT vehicles built before June 2, 2006 (MDH 0602XX) SYMPTOM/CONDITION: The rear wiper may stop operating. Upon further investigation the technician may find that the following Diagnostic Trouble Codes (DTC's) are present:: A. B2215 - FCM Internal B. B231B - Rear Wiper Motor Control Circuit Low DIAGNOSIS: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > System Information > Technical Service Bulletins > All Technical Service Bulletins for Relays and Modules - Wiper and Washer Systems: > Page 497 1. Connect the StarSCAN(R) to the vehicle. 2. Turn the ignition on. 3. With the Scan Tool, clear all TIPM DTC's. 4. Turn the Rear Windshield Wipers on. 5. Does the rear wiper operate? 6. Yes >> Perform the Repair Procedure. 7. No >> This bulletin does not apply, additional diagnosis is required. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 6.06 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old TIPM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the appropriate ECU in the list of modules. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > System Information > Technical Service Bulletins > All Technical Service Bulletins for Relays and Modules - Wiper and Washer Systems: > Page 498 c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash ECU" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Highlight the listed calibration. h. Select "Download to Scantool". i. Select "Close" after the download is complete, then select "Back". j. Highlight the listed calibration. k. Select "Update Controller". Follow on screen instructions. l. When the update is complete, select "OK". m. Verify the part number at the top of the "Flash ECU" screen has updated to the new part number. NOTE: Due to the TIPM programming procedure, a DTC may be set in other modules (PCM, TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Description and Operation Integrated Accessory Switch Assembly: Description and Operation DESCRIPTION There is an Accessory Switch Bank Module (ASBM) located in the instrument panel center stack just below the heater a/c control. Included in this switch bank are: - Electronic Stability Program (ESP)/Traction Control Switch (TCS) Off (if equipped) - Hazard Switch (all models) - Heated Seat Switch (if equipped) - Passenger Airbag Disabled Lamp (PADL) Indicator (if equipped with OCS) The BUX version of the ASBM will vary from the domestic a bit. Following are the various BUX switches: - Anti-Skid Control (ASC) (if equipped) - This is the same as the ESP/TCS off switch in the domestic version. - Hazard Switch (all models) - Heated Seat Switch (if equipped) - Headlamp Leveling Switch (if equipped) Each individual switch is not available for service replacement. If one or more switches are inoperative, the entire ASBM must be replaced. To diagnose the ASBM switches, use a scan tool and the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Service and Repair > Removal Integrated Accessory Switch Assembly: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel center bezel. 3. Remove the screws to the Accessory Switch Bank Module (ASBM) (4). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Service and Repair > Removal > Page 506 Integrated Accessory Switch Assembly: Service and Repair Installation INSTALLATION 1. Position the Accessory Switch Bank Module (ASBM) (4) in the center bezel. 2. Install the screws to the ASBM. 3. Install the instrument panel center bezel. 4. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Description Remote Switch: Description and Operation Description DESCRIPTION Two rocker-type switches (if equipped) are mounted on the back (instrument panel side) of the steering wheel spokes. The switch on the left spoke is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right spoke is the volume control switch and has volume up, and volume down functions. The switch on the right spoke also includes a "mode" control that allows the driver to sequentially select AM radio, FM radio, cassette player, CD player or CD changer (if equipped). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Description > Page 511 Remote Switch: Description and Operation Operation OPERATION These switches are resistor multiplexed units that are hard-wired to the Cab Compartment Node (CCN) through the clockspring. The CCN sends the proper messages on the Controller Area Network (CAN) data bus network to the radio receiver. For diagnosis of the CCN or the CAN data bus, the use of a scan tool and the proper Diagnostic Procedures manual are recommended. For more information on the operation of the remote radio switch controls, refer to the owner's manual in the vehicle glove box. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Page 512 Remote Switch: Testing and Inspection REMOTE SWITCHES WARNING: On vehicles equipped with airbags, refer to electrical, restraints before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. Any diagnosis of the Audio system should begin with the use of the scan tool. For information on the use of the scan tool, refer to the appropriate Diagnostic Manual. For complete circuit diagrams, refer to the appropriate wiring information. 1. Disconnect and isolate the battery negative cable. 2. Remove the remote radio switch(es) from the steering wheel. 3. Use an ohmmeter to check the switch resistance as shown in the Remote Radio Switch Test table NOTE: The right remote radio switch back is white in color. The left switch back is black in color. The right/left remote radio switch orientation is with the steering wheel installed, and driver in driver's seat. 4. If the switch resistance checks OK, go to STEP 5. If not OK, replace the faulty switch. 5. Check for continuity between the ground circuit cavity of the switch wire harness connector and a good ground. There should be continuity. If OK, go to STEP 6. If not OK, repair the open circuit as required. 6. Unplug the connector from the Cab Compartment Node (CCN). Check for continuity between the radio control circuit cavity of the remote radio switch wire harness connector and a good ground. There should be no continuity. If OK, go to STEP 7. If not OK, repair the short circuit as required. 7. Check for continuity between the radio control circuit cavities of the remote radio switch wire harness connector and the CCN wire harness connector. There should be continuity. If OK, refer to the proper Diagnostic Procedures manual to test the CCN and the CAN data bus. If not OK, repair the open circuit as required. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Service and Repair > Removal Remote Switch: Service and Repair Removal REMOVAL WARNING: On vehicles equipped with airbags, refer to electrical, restraints before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. 1. Disconnect and isolate the battery negative cable. 2. Remove the driver side airbag. 3. Remove the steering wheel. 4. Unplug the wire harness connector from the remote radio switch. 5. Remove steering wheel rear cover. 6. Remove the remote radio switch from the steering wheel by depressing tabs on each side of each switch. NOTE: The right remote radio switch back is white in color. The left switch back is black in color. The right/left remote radio switch orientation is with the steering wheel installed, and driver in driver's seat. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Service and Repair > Removal > Page 515 Remote Switch: Service and Repair Installation INSTALLATION WARNING: On vehicles equipped with airbags, refer to electrical, restraints before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. 1. Install remote radio switch to the steering wheel. 2. Install steering wheel rear cover. 3. Connect the wire harness to the remote radio switch. 4. Install the steering wheel. 5. Install the driver side airbag. 6. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection Power Door Lock Switch: Testing and Inspection DOOR LOCK SWITCH 1. Remove the switch. 2. Using an ohmmeter, refer to Door Lock Switch Test table to determine if switch resistance is correct in the Lock and Unlock switch positions. Refer to Wiring Diagrams for harness connector pin-outs. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Removal Power Door Lock Switch: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the front door bolster. 3. Disconnect the electrical harness connectors. 4. With the bolster on the bench, gently pry in on the tabs of the mirror switch and push through the front of the cover and remove. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Removal > Page 522 Power Door Lock Switch: Service and Repair Installation INSTALLATION 1. Place the mirror switch in bolster opening and firmly snap into place. 2. Connect the electrical harness connectors. 3. Install the front door bolster. 4. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations Power Mirror Switch: Locations Component ID: 346 Component : SWITCH-MIRROR Connector: Name : SWITCH-MIRROR Color : BLACK # of pins : 10 Qualifier : (LHD) Pin Description Circuit 1-2-3 MIRROR COMMON DRIVER P76 20YL/PK 4 GROUND Z928 20BK/LG 5 FUSED B(+) (I.O.D.) A417 20RD/DG 6 RIGHT MIRROR VERTICAL DRIVER P72 20TN/GY 7 LEFT MIRROR VERTICAL DRIVER P71 20TN/DG 8 RIGHT MIRROR HORIZONTAL DRIVER P74 20TN/OR 9 LEFT MIRROR HORIZONTAL DRIVER P75 20TN/OR 10 - Component Location - 54 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 526 Connector: Name : SWITCH-MIRROR Color : # of pins : 10 Qualifier : (RHD) Pin Description Circuit 1 FOLDING MIRROR RETURN P110 20LG/WT 2-3 MIRROR COMMON DRIVER P76 20YL/PK 4 GROUND Z928 20BK/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 527 5 FUSED B(+) (I.O.D.) A417 20RD/DG 6 RIGHT MIRROR VERTICAL DRIVER P72 20TN/GY 7 LEFT MIRROR VERTICAL DRIVER P71 20TN/DG 8 RIGHT MIRROR HORIZONTAL DRIVER P74 20TN/OR 9 LEFT MIRROR HORIZONTAL DRIVER P75 20TN/OR 10 MIRROR-POWER FOLDING/UNFOLDING P699 20LG/DG Component Location - 54 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 528 Power Mirror Switch: Diagrams Component ID: 346 Component : SWITCH-MIRROR Connector: Name : SWITCH-MIRROR Color : BLACK # of pins : 10 Qualifier : (LHD) Pin Description Circuit 1-2-3 MIRROR COMMON DRIVER P76 20YL/PK 4 GROUND Z928 20BK/LG 5 FUSED B(+) (I.O.D.) A417 20RD/DG 6 RIGHT MIRROR VERTICAL DRIVER P72 20TN/GY 7 LEFT MIRROR VERTICAL DRIVER P71 20TN/DG 8 RIGHT MIRROR HORIZONTAL DRIVER P74 20TN/OR 9 LEFT MIRROR HORIZONTAL DRIVER P75 20TN/OR 10 - Component Location - 54 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 529 Connector: Name : SWITCH-MIRROR Color : # of pins : 10 Qualifier : (RHD) Pin Description Circuit 1 FOLDING MIRROR RETURN P110 20LG/WT 2-3 MIRROR COMMON DRIVER P76 20YL/PK 4 GROUND Z928 20BK/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 530 5 FUSED B(+) (I.O.D.) A417 20RD/DG 6 RIGHT MIRROR VERTICAL DRIVER P72 20TN/GY 7 LEFT MIRROR VERTICAL DRIVER P71 20TN/DG 8 RIGHT MIRROR HORIZONTAL DRIVER P74 20TN/OR 9 LEFT MIRROR HORIZONTAL DRIVER P75 20TN/OR 10 MIRROR-POWER FOLDING/UNFOLDING P699 20LG/DG Component Location - 54 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 531 Power Mirror Switch: Testing and Inspection POWER MIRROR SWITCH - LHD 1. Disconnect and isolate the battery negative cable. 2. Remove power mirror switch. 3. Using an ohmmeter, test for continuity between the terminals of the switch as shown in the Mirror Switch Test table. 4. If test results are not obtained as shown in the Mirror Switch Test table, replace the switch. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 532 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 533 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Removal Power Mirror Switch: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the front door bolster. 3. Disconnect the electrical harness connectors. 4. With the bolster on the bench, gently pry in on the tabs of the mirror switch and push through the front of the cover and remove. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Removal > Page 536 Power Mirror Switch: Service and Repair Installation INSTALLATION 1. Place the mirror switch in bolster opening and firmly snap into place. 2. Connect the electrical harness connectors. 3. Install the front door bolster. 4. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Description Seat Heater Switch: Description and Operation Description DESCRIPTION The heated seat switches are located in the center stack (1) of the instrument panel. The switches are located on the outer edges of the accessory switch bank (2). If either of the switches is damaged or inoperative the complete accessory switch bank assembly must be replaced. When either of the heated seat switches are depressed a switch status message is sent to the Cab Compartment Node (CCN) or instrument cluster via the Local Interface Network (LIN) data bus. The CCN then sends a message via the LIN data bus to the heated seat module, signaling the module to energize the heating element for the selected seat. Amber Light Emitting Diodes (LEDs) in the top portion of each switch indicate the level of heat in use: Two LEDs are illuminated for high, one for low, and none for off. The heated seat module sends the LED illumination message to the CCN via the LIN data bus. The CCN then sends the LED illumination message to the accessory switch bank so that the appropriate LEDs are illuminated for any given heating level. Pressing the switch once will select high-level heating. Pressing the switch a second time will select low-level heating. Pressing the switch a third time will shut the heating elements off. The LED indicator lamps in each heated seat switch cannot be repaired. If the LED lamps are inoperative or damaged, or the switch is inoperative or damaged the complete accessory switch bank assembly must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Description > Page 541 Seat Heater Switch: Description and Operation Operation OPERATION The heated seat switches are active any time the Local Interface Network (LIN) data bus is active. Depressing the heated seat switch provides a switch status message to the Cabin Compartment Node (CCN) via the LIN data bus. The CCN is responsible for supplying the LIN data bus message to the heated seat module, signaling the module to power the heated seat element of the selected seat and maintain the temperature setting. If the heated seat switch is depressed to a different position (Low or High) than the currently selected state, the CCN will go through the process again to change the temperature setting. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Page 542 Seat Heater Switch: Testing and Inspection HEATED SEAT SWITCH In order to obtain conclusive testing, the heated seat system and the Local Interface Network (LIN) data bus circuit must be checked. Any diagnosis of the heated seat system should begin with, the use of a scan tool and the appropriate diagnostic information. Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. NOTE: Vehicles equipped with the heated seat option utilize a low voltage cut-off feature. This feature turns off power to the heated seat system anytime vehicle voltage is below 11.7v or above 15.5v. Be certain to check the vehicle electrical system for proper voltage anytime the power seat system appears inoperative. Before any testing of the heated seat system is attempted, the battery should be fully-charged. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Removal Seat Heater Switch: Service and Repair Removal REMOVAL WARNING: On vehicles equipped with airbags, disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. NOTE: The heated seat switches are integral to the accessory switch bezel and cannot be serviced separately. 1. Disconnect and isolate the negative battery cable. 2. Remove the center bezel from the instrument panel and place it on a work bench. 3. Remove the screws that secure the accessory switch bank (4) to the back of the center bezel and remove the accessory switch bank. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Removal > Page 545 Seat Heater Switch: Service and Repair Installation INSTALLATION NOTE: There are different instrument panel accessory switch banks available based on the option content of the vehicle. Ensure the accessory switch bank being installed matches the vehicle options. 1. Position the accessory switch bank (4) onto the back of the instrument panel center bezel. 2. Install the screws that secure the accessory switch bank to the center bezel. Tighten the screws to 1 Nm (8 in. lbs.). 3. Install the center bezel onto the instrument panel. 4. Reconnect the negative battery cable. 5. Verify heated seat system operation. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Description and Operation > Description Sunroof / Moonroof Switch: Description and Operation Description DESCRIPTION The power sunroof switch (2) is a combination push-button and rocker switch module mounted in the Courtesy/Reading Lamp assembly (1). The sunroof switch is a direct contact unit that is directly wired to the sunroof motor/module assembly. The sunroof switch performs the following functions: - Power sunroof open (back of switch pushed) - Power sunroof express open (back of switch pushed and released) - Power sunroof closed (front of switch pushed) - Power sunroof express closed (front of switch pushed and released) - Power sunroof vent (switch center button pushed) The power sunroof switch cannot be repaired. If the individual components are damaged or inoperative the switch assembly must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Description and Operation > Description > Page 550 Sunroof / Moonroof Switch: Description and Operation Operation OPERATION The sunroof is electrically operated from two switches located in the headliner on the courtesy/reading lamp assembly. The power sunroof switch is hard wired to the sunroof motor/module assembly. The "VENT" switch is a push button type switch and opens the sunroof to the vent position only. The other switch "OPEN/CLOSED" is a rocker type switch for opening and closing the sunroof. Pressing and releasing the open button once, the sunroof will express open and the wind deflector will raise. If the button is pressed a second time the sunroof will stop in that position. Pressing and releasing the close button once will express close the sunroof. If the close button is pressed a second time during the express close operation the sunroof will stop in that position. The switch is grounded at one terminal and receives a 5 volt signal from the sunroof motor/module on the remaining three terminals. The switch pulls down the 5 volt reference voltage from the module signaling it to perform the desired function. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Testing and Inspection > Control Switch Sunroof / Moonroof Switch: Testing and Inspection Control Switch CONTROL SWITCH The following test will determine if the sunroof control switch is operating properly. 1. Remove the sunroof control switch from the overhead console. 2. Using an ohmmeter, test the switch terminals for proper continuity using the table below. If any of the terminals do not show proper continuity, replace the sunroof control switch. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Testing and Inspection > Control Switch > Page 553 Sunroof / Moonroof Switch: Testing and Inspection Sunroof Switch SUNROOF SWITCH For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Remove the power sunroof switch. 2. Disconnect the power sunroof switch wire harness connector. 3. With the ignition key in the "RUN" position check for 5 volts on the "OPEN", "CLOSE" and "VENT" circuits of the sunroof switch harness connector. If OK, go to STEP 4. If not OK, inspect the wiring harness and connectors between the motor/module and switch for damage and repair as necessary. 4. With the ignition key in the "OFF" position check for continuity between the ground circuit of the sunroof switch harness connector and a known good ground. Continuity should be present. If OK, go to STEP 5. If not OK, inspect the wiring harness and connector and repair the ground circuit as necessary. 5. Using an ohmmeter, test the continuity of the power sunroof switch in each switch position. If OK, inspect the wiring harness and connectors for damage and repair as necessary. If not OK, replace the power sunroof switch. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Removal Sunroof / Moonroof Switch: Service and Repair Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the courtesy/reading lamp lens (5). Insert a suitable flat bladed tool into the slot (6) in the courtesy/reading lamp assembly (2). Pivot the lens down and to the left to release the holding tab (4). 3. Using a suitable flat bladed tool, release the mounting tabs (5) from the sides of the sunroof control switch (4) and pull the switch down from the courtesy/reading lamp assembly (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Removal > Page 556 4. Disconnect the electrical connector (3) from the sunroof control switch (4). 5. Remove the switch from the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Removal > Page 557 Sunroof / Moonroof Switch: Service and Repair Installation INSTALLATION 1. Position the sunroof control switch (4) into the vehicle. 2. Connect the sunroof control switch electrical connector (3). 3. Insert the sunroof control switch (4) into the courtesy/reading lamp assembly (2). Push up on the switch until it is securely held in place by the mounting tabs (5). 4. Insert the mounting tab (4) on the lamp lens (5) into the right side of the lamp assembly and pivot the lens up until it snaps securely in place. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Removal > Page 558 5. Connect the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Brake Fluid Level Sensor/Switch: Locations Component ID: 283 Component : SENSOR-BRAKE FLUID LEVEL Connector: Name : SENSOR-BRAKE FLUID LEVEL Color : BLACK # of pins : 2 Pin Description Circuit 1 BRAKE FLUID LEVEL SWITCH SENSE B20 20DG/RD 2 GROUND Z925 20BK/YL Component Location - 6 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 563 Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 564 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 565 Brake Fluid Level Sensor/Switch: Diagrams Component ID: 283 Component : SENSOR-BRAKE FLUID LEVEL Connector: Name : SENSOR-BRAKE FLUID LEVEL Color : BLACK # of pins : 2 Pin Description Circuit 1 BRAKE FLUID LEVEL SWITCH SENSE B20 20DG/RD 2 GROUND Z925 20BK/YL Component Location - 6 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 566 Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 567 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 568 Brake Fluid Level Sensor/Switch: Description and Operation DESCRIPTION The brake fluid level switch (2) is mounted through the center of the fluid reservoir (1). The switch can be serviced separately from the master cylinder fluid reservoir. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Service and Repair > Removal Brake Fluid Level Sensor/Switch: Service and Repair Removal REMOVAL NOTE: Refer to Warnings and Cautions. 1. Remove the wiring harness connector (1) from the brake fluid level switch (2) in the master cylinder brake fluid reservoir. 2. Push together the retaining tabs (1) holding the brake fluid level switch in place in the brake fluid reservoir (2). 3. Pull the brake fluid level switch out the right side of the reservoir. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Service and Repair > Removal > Page 571 Brake Fluid Level Sensor/Switch: Service and Repair Installation INSTALLATION 1. Align the brake fluid level switch with its mounting hole on the right side of the master cylinder brake fluid reservoir. Push the switch into the fluid reservoir until the switch retaining tabs (1) are expanded on the opposite side of the reservoir (2), locking it in place. 2. Connect the wiring harness connector (1) to the switch (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations Lateral Accelerometer: Locations Component ID: 288 Component : SENSOR-DYNAMICS Connector: Name : SENSOR-DYNAMICS Color : BLACK # of pins : 6 Qualifier : (ESP) Pin Description Circuit 1 DYNAMICS SENSOR LOW DATA LINK D464 20WT/YL 2 DYNAMICS SENSOR HIGH DATA LINK D465 20WT/DB 3 DYNAMICS SENSOR SUPPLY G4 18VT/LB 4-5 DYNAMICS SENSOR GROUND G94 18VT/DB 6-- Component Location - 45 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations > Page 575 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations > Page 576 Lateral Accelerometer: Diagrams Component ID: 288 Component : SENSOR-DYNAMICS Connector: Name : SENSOR-DYNAMICS Color : BLACK # of pins : 6 Qualifier : (ESP) Pin Description Circuit 1 DYNAMICS SENSOR LOW DATA LINK D464 20WT/YL 2 DYNAMICS SENSOR HIGH DATA LINK D465 20WT/DB 3 DYNAMICS SENSOR SUPPLY G4 18VT/LB 4-5 DYNAMICS SENSOR GROUND G94 18VT/DB 6-- Component Location - 45 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations > Page 577 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations > Page 578 Lateral Accelerometer: Description and Operation DESCRIPTION The Yaw Rate and Lateral Acceleration Sensors are housed into one unit known as the Dynamics Sensor (1). The sensor is used to measure side-to-side (Lateral) motion and vehicle rotational sensing (how fast the vehicle is turning - Yaw). Yaw and Lateral Acceleration Sensors cannot be serviced separately. The entire Dynamics Sensor must be replaced when necessary. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Service and Repair > Removal Lateral Accelerometer: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable from the battery post. 2. Remove the shifter housing center console. 3. Disconnect the wiring harness connector (3) at the dynamics sensor (1). 4. Remove the nuts (2) mounting the dynamics sensor to the floor pan tunnel (4). 5. Remove the dynamics sensor (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Service and Repair > Removal > Page 581 Lateral Accelerometer: Service and Repair Installation INSTALLATION 1. Install the dynamics sensor (1) over the studs mounted to the floor pan tunnel (4). 2. Install the two mounting nuts (2). Tighten the nuts to 9 Nm (80 in. lbs.). 3. Connect the wiring harness connector (3) to the dynamics sensor (1). 4. Install the shifter housing center console. 5. Connect the battery negative cable to the battery post. It is important that this be performed properly. 6. Perform the Verification Test and clear any faults. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Component ID: 348 Component : SWITCH-PARKING BRAKE Connector: Name : SWITCH-PARKING BRAKE Color : NATURAL # of pins : 1 Pin Description Circuit 1 PARK BRAKE SWITCH SENSE B25 20DG/WT Component Location - 35 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 585 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 586 Parking Brake Warning Switch: Diagrams Component ID: 348 Component : SWITCH-PARKING BRAKE Connector: Name : SWITCH-PARKING BRAKE Color : NATURAL # of pins : 1 Pin Description Circuit 1 PARK BRAKE SWITCH SENSE B25 20DG/WT Component Location - 35 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 587 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Locations Steering Angle Sensor: Locations Component ID: 316 Component : SENSOR-STEERING ANGLE Connector: Name : SENSOR-STEERING ANGLE Color : WHITE # of pins : 4 Pin Description Circuit 1 CAN C BUS (+) D265 20DB/LB 2 CAN C BUS (-) D264 20DB/WT 3 GROUND Z937 20BK/YL 4 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY Component Location - 28 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Locations > Page 591 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Locations > Page 592 Steering Angle Sensor: Diagrams Component ID: 316 Component : SENSOR-STEERING ANGLE Connector: Name : SENSOR-STEERING ANGLE Color : WHITE # of pins : 4 Pin Description Circuit 1 CAN C BUS (+) D265 20DB/LB 2 CAN C BUS (-) D264 20DB/WT 3 GROUND Z937 20BK/YL 4 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY Component Location - 28 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Locations > Page 593 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Locations > Page 594 Steering Angle Sensor: Description and Operation DESCRIPTION The steering angle sensor is an integral part of the clockspring (3) mounted on the steering column. Refer to CLOCKSPRING - DESCRIPTION) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Description and Operation Traction Control Switch: Description and Operation DESCRIPTION The ESP Off Switch is part of the accessory switch bank module located in the center bezel on the instrument panel above the transmission gear shifter. The ESP Off switch turns the Electronic Stability Program off whenever the switch is depressed. Depressing the switch a second time turns the ESP(R) back on. The switch resets itself each time the ignition is cycled. When the ESP Off switch is depressed and released, turning ESP(R) off, it does not completely turn the system off. The ESP(R) system reduces torque management to a lesser amount, but ESP(R) function can still occur if the system perceives the need. The ESP Off switch is serviced as part of the accessory switch bank. There are different accessory switch banks available based on the option content of the vehicle. Ensure the accessory switch bank being installed matches the vehicle options. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Service and Repair > Removal Traction Control Switch: Service and Repair Removal REMOVAL NOTE: The ESP Off switch is integral to the accessory switch bank and cannot be serviced separately. 1. Disconnect and isolate the negative battery cable. 2. Remove the center bezel from the instrument panel and place it on a work bench. 3. Remove the screws that secure the accessory switch bank to the back of the center bezel and remove the accessory switch bank. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Service and Repair > Removal > Page 600 Traction Control Switch: Service and Repair Installation INSTALLATION NOTE: The ESP Off switch is serviced as part of the accessory switch bank. NOTE: There are different instrument panel accessory switch banks available based on the option content of the vehicle. Ensure the accessory switch bank being installed matches the vehicle options. 1. Position the accessory switch bank onto the back of the instrument panel center bezel. 2. Install the screws that secure the accessory switch bank to the center bezel. Tighten the screws to 2 Nm (17 in. lbs.). 3. Install the center bezel onto the instrument panel. 4. Reconnect the negative battery cable. 5. Perform the ABS Verification Test and make sure the ESP Off switch operates properly. 6. Verify proper operation of all components controlled by the switch bank. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front Wheel Speed Sensor: Locations Sensor-Wheel Speed-ABS-Left Front Component ID: 319 Component : SENSOR-WHEEL SPEED-ABS-LEFT FRONT Connector: Name : SENSOR-WHEEL SPEED-ABS-LEFT FRONT Color : BLACK # of pins : 2 Pin Description Circuit 1 LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY B9 20DG/LG 2 LEFT FRONT WHEEL SPEED SENSOR SIGNAL B8 20DG/TN Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 605 Connector: Name : SENSOR-WHEEL SPEED-ABS-LEFT FRONT Color : # of pins : 2 Qualifier : (SENSOR SIDE) Pin Description Circuit 1 LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY DG/LG 2 LEFT FRONT WHEEL SPEED SENSOR SIGNAL DG/TN Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 606 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 607 Wheel Speed Sensor: Locations Sensor-Wheel Speed-ABS-Left Rear Component ID: 320 Component : SENSOR-WHEEL SPEED-ABS-LEFT REAR Connector: Name : SENSOR-WHEEL SPEED-ABS-LEFT REAR Color : BLACK # of pins : 2 Pin Description Circuit 1 LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY B4 20LG/BK 2 LEFT REAR WHEEL SPEED SENSOR SIGNAL B3 20LG/DB Component Location - 60 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 608 Connector: Name : SENSOR-WHEEL SPEED-ABS-LEFT REAR Color : # of pins : 2 Qualifier : (SENSOR SIDE) Pin Description Circuit 1 LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY LG 2 LEFT REAR WHEEL SPEED SENSOR SIGNAL LG/DB Component Location - 60 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 609 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 610 Wheel Speed Sensor: Locations Sensor-Wheel Speed-ABS-Right Front Component ID: 321 Component : SENSOR-WHEEL SPEED-ABS-RIGHT FRONT Connector: Name : SENSOR-WHEEL SPEED-ABS-RIGHT FRONT Color : BLACK # of pins : 2 Pin Description Circuit 1 RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY B7 20WT 2 RIGHT FRONT WHEEL SPEED SENSOR SIGNAL B6 20WT/DB Component Location - 5 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 611 Component Location - 6 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 612 Connector: Name : SENSOR-WHEEL SPEED-ABS-RIGHT FRONT Color : # of pins : 2 Qualifier : (SENSOR SIDE) Pin Description Circuit 1 RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY WT 2 RIGHT FRONT WHEEL SPEED SENSOR SIGNAL WT/DB Component Location - 5 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 613 Component Location - 6 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 614 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 615 Wheel Speed Sensor: Locations Sensor-Wheel Speed-ABS-Right Rear Component ID: 322 Component : SENSOR-WHEEL SPEED-ABS-RIGHT REAR Connector: Name : SENSOR-WHEEL SPEED-ABS-RIGHT REAR Color : BLACK # of pins : 2 Pin Description Circuit 1 RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY B2 20DG/LB 2 RIGHT REAR WHEEL SPEED SENSOR SIGNAL B1 20DG/OR 2 RIGHT REAR WHEEL SPEED SENSOR SIGNAL B1 20YL/DB Component Location - 63 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 616 Connector: Name : SENSOR-WHEEL SPEED-ABS-RIGHT REAR Color : # of pins : 2 Qualifier : (SENSOR SIDE) Pin Description Circuit 1 RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY DG/LB 2 RIGHT REAR WHEEL SPEED SENSOR SIGNAL DG/OR Component Location - 63 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 617 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front Wheel Speed Sensor: Diagrams Sensor-Wheel Speed-ABS-Left Front Component ID: 319 Component : SENSOR-WHEEL SPEED-ABS-LEFT FRONT Connector: Name : SENSOR-WHEEL SPEED-ABS-LEFT FRONT Color : BLACK # of pins : 2 Pin Description Circuit 1 LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY B9 20DG/LG 2 LEFT FRONT WHEEL SPEED SENSOR SIGNAL B8 20DG/TN Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 620 Connector: Name : SENSOR-WHEEL SPEED-ABS-LEFT FRONT Color : # of pins : 2 Qualifier : (SENSOR SIDE) Pin Description Circuit 1 LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY DG/LG 2 LEFT FRONT WHEEL SPEED SENSOR SIGNAL DG/TN Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 621 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 622 Wheel Speed Sensor: Diagrams Sensor-Wheel Speed-ABS-Left Rear Component ID: 320 Component : SENSOR-WHEEL SPEED-ABS-LEFT REAR Connector: Name : SENSOR-WHEEL SPEED-ABS-LEFT REAR Color : BLACK # of pins : 2 Pin Description Circuit 1 LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY B4 20LG/BK 2 LEFT REAR WHEEL SPEED SENSOR SIGNAL B3 20LG/DB Component Location - 60 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 623 Connector: Name : SENSOR-WHEEL SPEED-ABS-LEFT REAR Color : # of pins : 2 Qualifier : (SENSOR SIDE) Pin Description Circuit 1 LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY LG 2 LEFT REAR WHEEL SPEED SENSOR SIGNAL LG/DB Component Location - 60 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 624 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 625 Wheel Speed Sensor: Diagrams Sensor-Wheel Speed-ABS-Right Front Component ID: 321 Component : SENSOR-WHEEL SPEED-ABS-RIGHT FRONT Connector: Name : SENSOR-WHEEL SPEED-ABS-RIGHT FRONT Color : BLACK # of pins : 2 Pin Description Circuit 1 RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY B7 20WT 2 RIGHT FRONT WHEEL SPEED SENSOR SIGNAL B6 20WT/DB Component Location - 5 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 626 Component Location - 6 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 627 Connector: Name : SENSOR-WHEEL SPEED-ABS-RIGHT FRONT Color : # of pins : 2 Qualifier : (SENSOR SIDE) Pin Description Circuit 1 RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY WT 2 RIGHT FRONT WHEEL SPEED SENSOR SIGNAL WT/DB Component Location - 5 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 628 Component Location - 6 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 629 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 630 Wheel Speed Sensor: Diagrams Sensor-Wheel Speed-ABS-Right Rear Component ID: 322 Component : SENSOR-WHEEL SPEED-ABS-RIGHT REAR Connector: Name : SENSOR-WHEEL SPEED-ABS-RIGHT REAR Color : BLACK # of pins : 2 Pin Description Circuit 1 RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY B2 20DG/LB 2 RIGHT REAR WHEEL SPEED SENSOR SIGNAL B1 20DG/OR 2 RIGHT REAR WHEEL SPEED SENSOR SIGNAL B1 20YL/DB Component Location - 63 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 631 Connector: Name : SENSOR-WHEEL SPEED-ABS-RIGHT REAR Color : # of pins : 2 Qualifier : (SENSOR SIDE) Pin Description Circuit 1 RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY DG/LB 2 RIGHT REAR WHEEL SPEED SENSOR SIGNAL DG/OR Component Location - 63 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 632 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Front Wheel Speed Wheel Speed Sensor: Description and Operation Front Wheel Speed Description DESCRIPTION The antilock brake system uses two-wire wheel speed sensors, known as active wheel speed sensors. The sensors use an electronic principle known as magnetoresistive to help increase performance and durability. The sensors convert wheel speed into a small digital signal. A Wheel Speed Sensor (WSS) is used at each wheel. A magnetic pole encoder serves as the trigger mechanism for each sensor. At each wheel of the vehicle there is one wheel speed sensor and one encoder. A front wheel speed sensor (3) is attached to a mounting boss on each front knuckle (4). The encoder is an integral part of the hub and bearing. WSS air gaps are not adjustable. Operation OPERATION The ABM sends 12 volts to power an Integrated Circuit (IC) in the sensor. The IC supplies a constant 7 mA power supply to the ABM. The relationship of the magnetic pole encoder to the permanent magnet in the sensor, signals the IC to enable a second 7 mA power supply. The output of the sensor, sent to the ABM, is a DC voltage signal with changing voltage and current levels. The ground for the IC and the current sense circuit is provided by the ABM. When a pole is properly aligned with the sensor, the voltage signal is approximately 0.8 volts and a constant 7 mA current is sent to the ABM. As the magnetic pole encoder rotates, the encoder shifts the magnetic field and the IC enables a second 7 mA current source. The ABM senses a voltage signal of approximately 1.6 volts and 14 mA. The ABM measures the amperage of the digital signal for each wheel. The resulting signal is interpreted by the ABM as the wheel speed. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Front Wheel Speed > Page 635 Wheel Speed Sensor: Description and Operation Rear Wheel Speed Description DESCRIPTION The antilock brake system uses two-wire wheel speed sensors, known as active wheel speed sensors. The sensors use an electronic principle known as magnetoresistive to help increase performance and durability. The sensors convert wheel speed into a small digital signal. A Wheel Speed Sensor (WSS) is used at each wheel. A magnetic pole encoder serves as the trigger mechanism for each sensor. At each wheel of the vehicle there is one wheel speed sensor and one encoder. On all-wheel-drive vehicles, the rear wheel speed sensor head (1) is secured to the rear hub and bearing (2) by a spring-loaded clip on the rear of the assembly. The encoder is integral to the hub and bearing assembly. The encoder is serviced as part of the rear hub and bearing. On front-wheel-drive vehicles, the rear wheel speed sensor head (3) is mounted to the rear of the hub and bearing by a screw. The encoder is integral to the hub and bearing assembly. The encoder is are serviced as part of the rear hub and bearing. The WSS air gaps are not adjustable. Operation OPERATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Front Wheel Speed > Page 636 The ABM sends 12 volts to power an Integrated Circuit (IC) in the sensor. The IC supplies a constant 7 mA power supply to the ABM. The relationship of the magnetic pole encoder to the permanent magnet in the sensor, signals the IC to enable a second 7 mA power supply. The output of the sensor, sent to the ABM, is a DC voltage signal with changing voltage and current levels. The ground for the IC and the current sense circuit is provided by the ABM. When a pole is properly aligned with the sensor, the voltage signal is approximately 0.8 volts and a constant 7 mA current is sent to the ABM. As the magnetic pole encoder rotates, the encoder shifts the magnetic field and the IC enables a second 7 mA current source. The ABM senses a voltage signal of approximately 1.6 volts and 14 mA. The ABM measures the amperage of the digital signal for each wheel. The resulting signal is interpreted by the ABM as the wheel speed. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Wheel Speed Sensor: Service and Repair Front Wheel Speed Removal REMOVAL NOTE: Refer to Warnings and Cautions. 1. Open the hood. 2. Disconnect the wheel speed sensor cable connector (2) from the wiring harness connector (3) on top of the frame rail (1) to the inside of the strut tower. 3. Raise and support the vehicle. 4. Remove the grommet (1) from the hole in the body (7) and pull the wheel speed sensor cable out of the hole. 5. Remove the speed sensor cable routing clip (2) from the outside frame rail (6). 6. Remove the screw fastening the cable routing clamp (3) to the outside frame rail (6). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 639 7. Remove the screw (1) securing the wheel speed sensor routing bracket (2) to the brake flex hose bracket (5). 8. Remove the mounting screw (2) fastening the wheel speed sensor head (3) to the knuckle (4). Pull the sensor head out of the knuckle. NOTE: In the following step, the routing clip can be easily removed without damaging it by rotating it (with entire sensor) counterclockwise. 9. Remove the routing clip (1) securing wheel speed sensor cable to the knuckle (4). Remove the sensor from the vehicle. Installation INSTALLATION CAUTION: Failure to install speed sensor cables properly may result in contact with moving parts or an over extension of cables causing an open circuit. Be sure that cables are installed, routed, and clipped properly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 640 1. Install the wheel speed sensor head (3) into the knuckle (4). Install the mounting screw (2) and tighten it to 12 Nm (106 in. lbs.). 2. Install the routing clip (1) securing the wheel speed sensor cable to the knuckle (4). 3. Position the wheel speed sensor routing bracket (2) on the brake flex hose bracket (5) and install the mounting screw (1). Tighten the mounting screw to 18 Nm (13 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 641 4. Position the wheel speed sensor cable routing clamp (4) on the outside frame rail (6) and install the mounting screw (3). Tighten the mounting screw to 18 Nm (13 ft. lbs.). 5. Install the speed sensor cable routing clip (2) on the outside frame rail (6). 6. Insert the wheel speed sensor cable through the hole in the body (7) and install the grommet (1) in the hole. 7. Lower the vehicle. 8. Connect the wheel speed sensor cable connector (2) to the wiring harness connector (3) on top of the frame rail (1). 9. Perform the Diagnostic Verification Test and clear any faults. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 642 Wheel Speed Sensor: Service and Repair Rear Wheel Speed All-Wheel-Drive ALL-WHEEL-DRIVE CAUTION: Failure to install speed sensor cables properly may result in contact with moving parts or an over extension of cables causing an open circuit. Be sure that cables are installed, routed, and clipped properly. NOTE: When installing the sensor head to the spring-loaded retainer on the hub and bearing, make sure the head is held snug in the retainer. If there is any play, the clip is deformed and the hub and bearing must be replaced. The retainer is not serviced separately. 1. Clip the wheel speed sensor head (1) (flat side to bearing rear face) into the spring-loaded retainer on the rear of the hub and bearing (2). 2. Position the wheel speed sensor (3) on the trailing link (2) and install the screw (4) securing it in place. Tighten the mounting screw to 18 Nm (13 ft. lbs.). 3. Position the wheel speed sensor (3) and install the routing clip (1) fastening the sensor to the trailing link (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 643 4. Position the wheel speed sensor cable routing clamp (3) on the rear suspension crossmember (4) and install the mounting screw (1). Tighten the mounting screw to 18 Nm (13 ft. lbs.). 5. Install the speed sensor cable routing clip (3) on the outside frame rail (4). NOTE: When inserting the wheel speed sensor cable through the hole in the body, route the cable toward the shock tower to make it easier to grasp the cable to connect it to the body wiring harness connector in a later step. 6. Insert the wheel speed sensor cable (5) through the hole in the body (1) and install the grommet (2) in the hole. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 644 7. Install the tire and wheel assembly (1). Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 8. Lower the vehicle. 9. Through the opening in the bottom of the quarter trim panel, connect the wheel speed sensor cable connector (2) to the body wiring harness connector (3). 10. If equipped, install the satellite receiver (1) or amplifier (2) to rear floor pan. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 645 11. Install the rear floor pan silencer (1). 12. Install the cargo floor cover. 13. Perform the Diagnostic Verification Test and clear any faults. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests Installation - FWD FRONT-WHEEL-DRIVE 1. Install the wheel speed sensor head (3) into the rear of the hub and bearing (2). 2. Install the wheel speed sensor head mounting screw (1). Tighten the screw to 10 Nm (89 in. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 646 3. Position the wheel speed sensor (3) on the trailing link (2) and install the screw (4) securing it in place. Tighten the mounting screw to 18 Nm (13 ft. lbs.). 4. Position the wheel speed sensor (3) and install the routing clip (1) fastening the sensor to the trailing link (2). 5. Position the wheel speed sensor cable routing clamp (3) on the rear suspension crossmember (4) and install the mounting screw (1). Tighten the mounting screw to 18 Nm (13 ft. lbs.). 6. Install the speed sensor cable routing clip (3) on the outside frame rail (4). NOTE: When inserting the wheel speed sensor cable through the hole in the body, route the cable toward the shock tower to make it easier to grasp the cable to connect it to the body wiring harness connector in a later step. 7. Insert the wheel speed sensor cable (5) through the hole in the body (1) and install the grommet (2) in the hole. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 647 8. Install the tire and wheel assembly (1). Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 9. Lower the vehicle. 10. Through the opening in the bottom of the quarter trim panel, connect the wheel speed sensor cable connector (2) at the body wiring harness connector (3). 11. If equipped, install the satellite receiver (1) or amplifier (2) to rear floor pan. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 648 12. Install the rear floor pan silencer (1). 13. Install the cargo floor cover. 14. Perform the Diagnostic Verification Test and clear any faults. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests All-Wheel-Drive ALL-WHEEL-DRIVE NOTE: Refer to Warnings and Cautions. 1. Remove the cargo floor cover. 2. Remove the rear floor pan silencer (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 649 3. If equipped, remove the nuts mounting the satellite receiver (1) or amplifier (2) to rear floor pan. Move the component aside to allow access to the wheel speed sensor wiring connector through the opening in bottom of the quarter trim panel. 4. Through the opening in the bottom of the quarter trim panel, disconnect the wheel speed sensor cable connector (2) at the body wiring harness connector (3). 5. Raise and support the vehicle. 6. Remove the wheel mounting nuts (3), then the rear tire and wheel assembly (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 650 7. Remove the grommet (2) from the hole in the body (1) and pull the wheel speed sensor cable out through the hole. 8. Remove the speed sensor cable routing clip (3) from the outside frame rail (4). 9. Remove the screw (1) fastening the cable routing clamp (3) to the rear suspension crossmember (4). 10. Remove the speed sensor cable routing clip (1) from the trailing link (2). 11. Remove the screw (4) fastening the cable routing clamp to the trailing link. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 651 12. Unclip the wheel speed sensor head (1) from the spring-loaded retainer on the rear of the hub and bearing (2). Remove the sensor from the vehicle. Removal - FWD FRONT-WHEEL-DRIVE NOTE: Refer to Warnings and Cautions. 1. Remove the cargo floor cover. 2. Remove the rear floor pan silencer (1). 3. If equipped, remove the nuts mounting the satellite receiver (1) or amplifier (2) to rear floor pan. Move the component aside to allow access to the wheel speed sensor wiring connector through the opening in bottom of the quarter trim panel. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 652 4. Through the opening in the bottom of the quarter trim panel, disconnect the wheel speed sensor cable connector (2) at the body wiring harness connector (3). 5. Raise and support the vehicle. 6. Remove the wheel mounting nuts (3), then the rear tire and wheel assembly (1). 7. Remove the grommet (2) from the hole in the body (1) and pull the wheel speed sensor cable out through the hole. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 653 8. Remove the speed sensor cable routing clip (3) from the outside frame rail (4). 9. Remove the screw (1) fastening the cable routing clamp (3) to the rear suspension crossmember (4). 10. Remove the speed sensor cable routing clip (1) from the trailing link (2). 11. Remove the screw (4) fastening the cable routing clamp to the trailing link. 12. Remove the screw (1) fastening the wheel speed sensor head (3) in the rear of the hub and bearing (2). Remove the sensor from the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations Yaw Rate Sensor: Locations Component ID: 288 Component : SENSOR-DYNAMICS Connector: Name : SENSOR-DYNAMICS Color : BLACK # of pins : 6 Qualifier : (ESP) Pin Description Circuit 1 DYNAMICS SENSOR LOW DATA LINK D464 20WT/YL 2 DYNAMICS SENSOR HIGH DATA LINK D465 20WT/DB 3 DYNAMICS SENSOR SUPPLY G4 18VT/LB 4-5 DYNAMICS SENSOR GROUND G94 18VT/DB 6-- Component Location - 45 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 657 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 658 Yaw Rate Sensor: Diagrams Component ID: 288 Component : SENSOR-DYNAMICS Connector: Name : SENSOR-DYNAMICS Color : BLACK # of pins : 6 Qualifier : (ESP) Pin Description Circuit 1 DYNAMICS SENSOR LOW DATA LINK D464 20WT/YL 2 DYNAMICS SENSOR HIGH DATA LINK D465 20WT/DB 3 DYNAMICS SENSOR SUPPLY G4 18VT/LB 4-5 DYNAMICS SENSOR GROUND G94 18VT/DB 6-- Component Location - 45 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 659 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 660 Yaw Rate Sensor: Description and Operation DESCRIPTION The Yaw Rate and Lateral Acceleration Sensors are housed into one unit known as the Dynamics Sensor (1). The sensor is used to measure side-to-side (Lateral) motion and vehicle rotational sensing (how fast the vehicle is turning - Yaw). Yaw and Lateral Acceleration Sensors cannot be serviced separately. The entire Dynamics Sensor must be replaced when necessary. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Service and Repair > Removal Yaw Rate Sensor: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable from the battery post. 2. Remove the shifter housing center console. 3. Disconnect the wiring harness connector (3) at the dynamics sensor (1). 4. Remove the nuts (2) mounting the dynamics sensor to the floor pan tunnel (4). 5. Remove the dynamics sensor (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Service and Repair > Removal > Page 663 Yaw Rate Sensor: Service and Repair Installation INSTALLATION 1. Install the dynamics sensor (1) over the studs mounted to the floor pan tunnel (4). 2. Install the two mounting nuts (2). Tighten the nuts to 9 Nm (80 in. lbs.). 3. Connect the wiring harness connector (3) to the dynamics sensor (1). 4. Install the shifter housing center console. 5. Connect the battery negative cable to the battery post. It is important that this be performed properly. 6. Perform the Verification Test and clear any faults. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor Coolant Temperature Sensor/Switch (For Computer): Technical Service Bulletins Engine Controls MIL On/DTC P0116/ECT Sensor NUMBER: 18-039-06 GROUP: Vehicle Performance DATE: December 6, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES FOR StarSCAN. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 7.02 SP2 OR HIGHER FOR THIS BULLETIN. SUBJECT: Flash: MIL Illumination DTC P0116 - Engine Coolant Temperature Sensor Performance OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) and the Transmission Control Module (1CM) with new software. CAUTION: VEHICLES EQUIPPED WITH A CVT TRANSMISSION MUST HAVE THE TRANSMISSION CONTROL MODULE (TCM) CHECKED FOR THE LATEST SOFTWARE LEVEL WHENEVER THE PCM SOFTWARE IS UPGRADED. IF NEWER TCM SOFTWARE IS AVAILABLE, IT MUST BE INSTALLED. MODELS: 2007 (PM) Caliber 2007 (MK49) Compass NOTE: This bulletin applies to PM/MK models equipped with a 1.8L, 2.0L or 2.4L gasoline engine (Sales Code EBA, ECN or ED3) and block heater (Sales Code NHK) built before November 20, 2006 (MDH 1120XX). NOTE: If an aftermarket or MOPAR accessory block heater is installed, the same conditions may apply. SYMPTOM/CONDITION: Some customers may experience MIL illumination after using the block heater. No other symptoms will be experienced. The technician may find the following DTC's: ^ P0116 - ENGINE COOLANT TEMPERATURE SENSOR PERFORMANCE DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If MIL illumination with DTC P0116 is present, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 670 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING **STEP 5n and/or 8h**. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 7.02 SP2 software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. PM/MK Models equipped with a CVT must have the TCM reprogrammed as follows: 6. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. 7. Is the TCM part number recorded in step 6e above, the same as the new p/n shown on the "Flash File List" screen? a. Yes >> No further action is necessary. Proceed to Step 9. b. No >> the TCM will require flash reprogramming, proceed to Step 8. 8. Flash reprogram the TCM as follows: a. From the "Flash File List" screen, select "Download to Scantool". b. Select "Close" after the download is complete, then select "Back". c. Highlight the listed calibration. d. Select "Update Controller". Follow on screen instructions. e. When the update is complete, select "OK". f. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. g. Turn the ignition switch to the OFF position for no less than 15 seconds. h. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 671 CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the TCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. ** NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 9. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Sensor-Engine Coolant Temperature 1 Coolant Temperature Sensor/Switch (For Computer): Locations Sensor-Engine Coolant Temperature 1 Component ID: 290 Component : SENSOR-ENGINE COOLANT TEMPERATURE 1 Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE 1 Color : DK. GRAY # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 SENSOR GROUND K900 20DB/DG 2 ECT 1 SIGNAL K2 20VT/OR Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Sensor-Engine Coolant Temperature 1 > Page 674 Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Sensor-Engine Coolant Temperature 1 > Page 675 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Sensor-Engine Coolant Temperature 1 > Page 676 Coolant Temperature Sensor/Switch (For Computer): Locations Sensor-Engine Coolant Temperature 2 Component ID: 291 Component : SENSOR-ENGINE COOLANT TEMPERATURE 2 Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE 2 Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 SENSOR GROUND K915 20BR/WT 2 ECT 2 SIGNAL K222 20BR/YL Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Sensor-Engine Coolant Temperature 1 > Page 677 Component Location - 15 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Sensor-Engine Coolant Temperature 1 > Page 678 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Sensor-Engine Coolant Temperature 1 Coolant Temperature Sensor/Switch (For Computer): Diagrams Sensor-Engine Coolant Temperature 1 Component ID: 290 Component : SENSOR-ENGINE COOLANT TEMPERATURE 1 Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE 1 Color : DK. GRAY # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 SENSOR GROUND K900 20DB/DG 2 ECT 1 SIGNAL K2 20VT/OR Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Sensor-Engine Coolant Temperature 1 > Page 681 Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Sensor-Engine Coolant Temperature 1 > Page 682 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Sensor-Engine Coolant Temperature 1 > Page 683 Coolant Temperature Sensor/Switch (For Computer): Diagrams Sensor-Engine Coolant Temperature 2 Component ID: 291 Component : SENSOR-ENGINE COOLANT TEMPERATURE 2 Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE 2 Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 SENSOR GROUND K915 20BR/WT 2 ECT 2 SIGNAL K222 20BR/YL Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Sensor-Engine Coolant Temperature 1 > Page 684 Component Location - 15 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Sensor-Engine Coolant Temperature 1 > Page 685 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations Cruise Control Switch: Locations Component ID: 357 Component : SWITCH-SPEED CONTROL Connector: Name : SWITCH-SPEED CONTROL Color : BLACK # of pins : 3 Pin Description Circuit 1 S/C SIGNAL 2 V72 20PK 2 S/C SIGNAL 1 V71 20VT 3 S/C SWITCH GROUND V937 20YL Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 690 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 691 Cruise Control Switch: Diagrams Component ID: 357 Component : SWITCH-SPEED CONTROL Connector: Name : SWITCH-SPEED CONTROL Color : BLACK # of pins : 3 Pin Description Circuit 1 S/C SIGNAL 2 V72 20PK 2 S/C SIGNAL 1 V71 20VT 3 S/C SWITCH GROUND V937 20YL Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 692 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Removal Cruise Control Switch: Service and Repair Removal REMOVAL WARNING: Do not place a non-deployed airbag face down on a hard surface, the airbag will propel into the air if accidentally deployed, and could result in serious or fatal injury. - Disconnect and isolate the battery negative (ground) cable before beginning steering wheel removal or installation. This will disable the front airbag system. Failure to disconnect the battery could result in accidental front airbag module deployment and possible personal injury. - Allow the front airbag system capacitor to discharge for two minutes before removing the steering wheel or any front airbag system component. The speed control switches is mounted in the steering wheel and wired through the clock spring device under the airbag module. 1. Adjust the steering wheel so that the tires are in the STRAIGHT-AHEAD position. 2. Remove the negative battery cable. 3. Turn off ignition. 4. Remove air bag. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Removal > Page 695 5. Disconnect the connector from the clockspring. 6. Remove the three mounting fasteners. 7. Remove the horn switch. 8. Remove 2 speed control switch mounting screws. 9. Disconnect the electrical connector. 10. Remove switch. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Removal > Page 696 Cruise Control Switch: Service and Repair Installation INSTALLATION The speed control switch is mounted in the steering wheel and wired through the clock spring device under the airbag module. 1. Connect the electrical connector to speed control switch. 2. Install the 2 speed control screw. 3. Tighten the screws (1) to 1.6 Nm (15 in. lbs.). Make sure rubber seal is in place around switch. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Removal > Page 697 4. Install the horn switch. 5. Install the three mounting fasteners. 6. Connect the electrical connector to the clockspring. 7. Install the driver airbag (3). WARNING: Do not connect battery negative cable yet. 8. Reconnect battery using Airbag System Test procedure in Restraints. 9. Close hood. 10. Verify vehicle and system operation. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Component ID: 341 Component : SWITCH-ENGINE OIL PRESSURE Connector: Name : SWITCH-ENGINE OIL PRESSURE Color : LT. GREEN # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 EOP SIGNAL G6 20VT/GY 2-Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 702 Component Location - 15 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 703 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 704 Oil Pressure Sender: Diagrams Component ID: 341 Component : SWITCH-ENGINE OIL PRESSURE Connector: Name : SWITCH-ENGINE OIL PRESSURE Color : LT. GREEN # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 EOP SIGNAL G6 20VT/GY 2-Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 705 Component Location - 15 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 706 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Description and Operation > Description Oil Pressure Sender: Description and Operation Description DESCRIPTION The oil pressure switch is located on the left front side of the engine block. The oil pressure switch is a pressure sensitive switch that is activated by the engine's oil pressure (in the main oil gallery). The switch is a two terminal device (one terminal is provided to the wiring harness and the other terminal is the switch's metal housing that screws into the engine block). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Description and Operation > Description > Page 709 Oil Pressure Sender: Description and Operation Operation OPERATION The oil pressure switch is normally "Closed." The switch changes from a "Closed" circuit to an "Open" circuit, on increasing pressure of 7 psig. The oil pressure switch changes from an "Open" circuit to a "Closed" circuit, on decreasing pressure, between 2 psig and 4 psig. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Service and Repair > Removal Oil Pressure Sender: Service and Repair Removal REMOVAL 1. Raise vehicle. 2. Disconnect electrical connector. 3. Remove oil pressure sensor using oil pressure socket C-4597 (1) and discard sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Service and Repair > Removal > Page 712 Oil Pressure Sender: Service and Repair Installation INSTALLATION NOTE: If the oil pressure sensor is removed, it must be replaced with a new sensor. CAUTION: The oil pressure sensor has tapered threads, over tightening could crack the engine block. 1. Install oil pressure sensor using oil pressure socket C-4597 (1) and tighten to 8 Nm (71 in. lbs.). 2. Connect electrical connector. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Locations Oil Temperature Sensor/Switch: Locations Component ID: 302 Component : SENSOR-OIL TEMPERATURE Connector: Name : SENSOR-OIL TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 EOT SIGNAL G24 20VT/BR 2 SENSOR GROUND K915 20BR/WT Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Locations > Page 716 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Locations > Page 717 Oil Temperature Sensor/Switch: Diagrams Component ID: 302 Component : SENSOR-OIL TEMPERATURE Connector: Name : SENSOR-OIL TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 EOT SIGNAL G24 20VT/BR 2 SENSOR GROUND K915 20BR/WT Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Locations > Page 718 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Service and Repair > Removal Oil Temperature Sensor/Switch: Service and Repair Removal REMOVAL 1. Disconnect oil temperature sensor (1) electrical connector. 2. Remove sensor (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Service and Repair > Removal > Page 721 Oil Temperature Sensor/Switch: Service and Repair Installation INSTALLATION 1. If re-using the oil temperature sensor, coat the threads with Mopar(R) thread sealant. 2. Install oil temperature sensor (1). Tighten to 18 Nm (160 in. lbs.). 3. Connect electrical connector. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Temperature Sensor / Switch HVAC: Locations Component ID: 282 Component : SENSOR-AMBIENT AIR TEMPERATURE Connector: Name : SENSOR-AMBIENT AIR TEMPERATURE Color : BLACK # of pins : 2 Pin Description Circuit 1 AAT SIGNAL G31 20VT/LG 2 AAT RETURN G931 20VT/DB Component Location - 10 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 726 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 727 Ambient Temperature Sensor / Switch HVAC: Diagrams Component ID: 282 Component : SENSOR-AMBIENT AIR TEMPERATURE Connector: Name : SENSOR-AMBIENT AIR TEMPERATURE Color : BLACK # of pins : 2 Pin Description Circuit 1 AAT SIGNAL G31 20VT/LG 2 AAT RETURN G931 20VT/DB Component Location - 10 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 728 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation > Description Ambient Temperature Sensor / Switch HVAC: Description and Operation Description DESCRIPTION The ambient temperature sensor is a variable resistor type sensor. It is mounted to the lower front fascia behind the radiator grille and in front of the engine compartment. The ambient temperature sensor cannot be adjusted or repaired and, if inoperative or damaged, it must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation > Description > Page 731 Ambient Temperature Sensor / Switch HVAC: Description and Operation Operation OPERATION The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal. The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the Totally Integrated Power Module (TIPM). Based upon the resistance in the sensor, the instrument cluster or Cab Compartment Node (CCN) display senses a specific voltage on the Controller Area Network (CAN) data bus circuit, which corresponds to a specific temperature. The compass/temperature display unit then displays the proper ambient temperature. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation > Page 732 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection AMBIENT TEMPERATURE SENSOR The thermometer function is supported by the ambient temperature sensor, the Totally Integrated Power Module (TIPM), the Controller Area Network (CAN) data bus circuit, and the instrument cluster or Cab Compartment Node (CCN) compass/temperature display unit. If the display shows "O" (-45° C (-49° F)) or "SC" (60° C (140° F)), there is an OPEN or SHORT CIRCUIT that must be repaired. The ambient temperature sensor circuit can also be diagnosed using the following Sensor Test, and Sensor Circuit Test. If the temperature sensor and circuit are confirmed to be OK, but the temperature display is inoperative or incorrect, replace the instrument cluster or CCN assembly. SENSOR TESTING 1. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. 2. Disconnect the ambient temperature sensor wire harness connector. 3. Measure the resistance of the ambient temperature sensor. At room temperature (approx. 20° C (68° F)), the sensor resistance should be between 9-11 Kilohms (9000-11000 ohms). The sensor resistance should read between these two values. If OK, refer to the appropriate diagnostic information to continue diagnosis of the Totally Integrated Power Module (TIPM), the Controller Area Network (CAN) data bus circuit, and the instrument cluster or CCN. If not OK, replace the inoperative ambient temperature sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Service and Repair > Removal Ambient Temperature Sensor / Switch HVAC: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the belly pan. 3. Disconnect the wire harness connector (1) from the ambient temperature sensor (2). 4. Remove the fastener that secures the ambient temperature sensor bracket to the front fascia. 5. Remove the ambient temperature sensor from the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Service and Repair > Removal > Page 735 Ambient Temperature Sensor / Switch HVAC: Service and Repair Installation INSTALLATION 1. Position the ambient temperature sensor in the vehicle. 2. Install the fastener that secures the ambient temperature sensor to the front fascia. 3. Connect the wire harness connector (1) to the ambient temperature sensor (2). 4. Install the belly pan. 5. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations Component ID: 292 Component : SENSOR-EVAPORATOR TEMPERATURE Connector: Name : SENSOR-EVAPORATOR TEMPERATURE Color : NATURAL # of pins : 2 Pin Description Circuit 1 EVAPORATOR TEMPERATURE SENSOR SIGNAL C21 20DB/LG 2 SENSOR GROUND C121 20DB/DG Component Location - 23 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 739 Fig. 23 Component Location - 24 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 740 Component Location - 26 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 741 Component Location - 29 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 742 Fig. 29 Component Location - 30 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 743 Component Location - 32 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 744 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 745 Evaporator Temperature Sensor / Switch: Diagrams Component ID: 292 Component : SENSOR-EVAPORATOR TEMPERATURE Connector: Name : SENSOR-EVAPORATOR TEMPERATURE Color : NATURAL # of pins : 2 Pin Description Circuit 1 EVAPORATOR TEMPERATURE SENSOR SIGNAL C21 20DB/LG 2 SENSOR GROUND C121 20DB/DG Component Location - 23 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 746 Fig. 23 Component Location - 24 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 747 Component Location - 26 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 748 Component Location - 29 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 749 Fig. 29 Component Location - 30 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 750 Component Location - 32 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 751 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Description Evaporator Temperature Sensor / Switch: Description and Operation Description DESCRIPTION The evaporator temperature sensor measures the temperature of the conditioned air downstream of the A/C evaporator. The evaporator temperature sensor is an electrical thermistor (1) mounted on the end of a molded plastic housing (2) that is inserted into the driver side of the HVAC housing near the coldest point of the A/C evaporator. The evaporator temperature sensor is retained in the HVAC housing by two integral retaining tabs (3) and is connected to the vehicle electrical system by use of a wire lead and connector (4) with two terminals. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Description > Page 754 Evaporator Temperature Sensor / Switch: Description and Operation Operation OPERATION The evaporator temperature sensor monitors the surface temperature of A/C evaporator and supplies an input signal to the A/C-heater control. The A/C-heater control uses the evaporator temperature sensor input signal to optimize A/C system performance and to protect the A/C system from evaporator freezing. The evaporator temperature sensor will change its internal resistance in response to the temperatures it monitors and is connected to the A/C-heater control through sensor ground circuit and a 5-volt reference signal circuit. As the temperature of the A/C evaporator decreases, the internal resistance of the evaporator temperature sensor decreases. The A/C-heater control uses the monitored voltage reading as an indication of evaporator temperature. The A/C-heater control is programmed to respond to this input by requesting the powertrain control module (PCM) or the engine control module (ECM) (depending on engine application) to adjust the compressor swash plate angle as necessary to optimize A/C system performance and to protect the A/C system from evaporator freezing. The evaporator temperature sensor is diagnosed using a scan tool. The evaporator temperature sensor cannot be adjusted or repaired and it must be replaced if found inoperative or damaged. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Service and Repair > Removal Evaporator Temperature Sensor / Switch: Service and Repair Removal REMOVAL NOTE: Illustration shown with air distribution housing removed for clarity. NOTE: It is not necessary to remove and disassemble the HVAC housing to service the evaporator temperature sensor. The evaporator temperature sensor can be removed for service from underneath the instrument panel. 1. Disconnect and isolate the negative battery cable. 2. Reach up under the driver side of the instrument panel and disconnect the electrical connector for the evaporator temperature sensor (1) from the instrument panel wire harness. 3. Using needle nose pliers, disengage the two retaining tabs (3) that secure the evaporator temperature sensor to the HVAC housing (2) by carefully pulling the sensor straight out of the side of the HVAC housing. 4. Route the electrical connector and wire lead of the evaporator temperature sensor out from under the heater core tubes and remove the sensor from the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Service and Repair > Removal > Page 757 Evaporator Temperature Sensor / Switch: Service and Repair Installation INSTALLATION NOTE: Illustration shown with air distribution housing removed for clarity. 1. Route the electrical connector and wire lead of the evaporator temperature sensor (1) under the heater core tubes located on the driver side of the HVAC housing (2). 2. Install the evaporator temperature sensor into the driver side of the HVAC housing. Make sure the retaining tabs (3) are fully engaged to the housing. 3. Connect the electrical connector for the evaporator temperature sensor to the instrument panel wire harness. 4. Reconnect the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Refrigerant Pressure Sensor / Switch: Locations Component ID: 360 Component : TRANSDUCER-A/C PRESSURE Connector: Name : TRANSDUCER-A/C PRESSURE Color : GRAY # of pins : 4 Pin Description Circuit 1 A/C PRESSURE SENSOR GROUND C918 20BK/LB 2 A/C PRESSURE SENSOR SUPPLY C818 20LB/TN 3 A/C PRESSURE SENSOR SIGNAL C18 20LB/BR 4-Component Location - 4 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 761 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 762 Refrigerant Pressure Sensor / Switch: Diagrams Component ID: 360 Component : TRANSDUCER-A/C PRESSURE Connector: Name : TRANSDUCER-A/C PRESSURE Color : GRAY # of pins : 4 Pin Description Circuit 1 A/C PRESSURE SENSOR GROUND C918 20BK/LB 2 A/C PRESSURE SENSOR SUPPLY C818 20LB/TN 3 A/C PRESSURE SENSOR SIGNAL C18 20LB/BR 4-Component Location - 4 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 763 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Description Refrigerant Pressure Sensor / Switch: Description and Operation Description DESCRIPTION The A/C pressure transducer (1) is a switch that is installed on a fitting located on the A/C discharge line. An internally threaded fitting on the A/C pressure transducer connects it to the externally threaded Schrader-type fitting on the A/C discharge line. A rubber O-ring seals the connection between the A/C pressure transducer and the discharge line fitting. The A/C pressure transducer is connected to the vehicle electrical system by a molded plastic connector with three terminals. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Description > Page 766 Refrigerant Pressure Sensor / Switch: Description and Operation Operation OPERATION The A/C pressure transducer monitors the pressures in the high side of the refrigerant system through its connection to a fitting on the A/C discharge line. The internal resistance of the A/C pressure transducer changes in response to the pressures it monitors. The totally integrated power module (TIPM) provides a five volt reference signal and a sensor ground to the A/C pressure transducer. The TIPM then monitors the output voltage of the transducer on a sensor return circuit to determine refrigerant pressure and sends a message to the powertrain control module (PCM) or the engine control module (ECM) (depending on engine application) over the CAN C BUS. The PCM/ECM is programmed to respond to this and other sensor inputs by controlling the operation of the swashplate within the A/C compressor and the radiator cooling fan to help optimize A/C system performance and to protect the system components from damage. The PCM adjusts the swashplate to nearly a zero degree angle (low compressor displacement) when high side pressure rises above 3130 kPa (454 psi) and re-adjusts the swashplate to a greater angle (higher compressor displacement) when high side pressure drops below 1999 kPa (290 psi). The A/C pressure transducer also reduces the swashplate angle if the high side pressure drops below 200 kPa (29 psi) and will increase the swashplate angle when the high side pressure rises above 234 262 kPa (34 - 38 psi). When the refrigerant pressure rises above 1655 kPa (240 psi), the PCM will actuate the cooling fan. A Schrader-type valve in the A/C discharge line fitting permits the A/C pressure transducer to be removed or installed without disturbing the refrigerant in the A/C system. The A/C pressure transducer is diagnosed using a scan tool. The A/C pressure transducer cannot be adjusted or repaired and must be replaced if found inoperative or damaged. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Removal Refrigerant Pressure Sensor / Switch: Service and Repair Removal REMOVAL NOTE: It is not necessary to discharge the refrigerant system to replace the A/C pressure transducer. NOTE: Typical A/C pressure transducer shown. 1. Disconnect and isolate the negative battery cable. 2. Carefully pull the top of the fascia forward to gain access to the A/C pressure transducer (2). 3. Reach down through the opening between the A/C condenser and the front fascia and disconnect the wire harness connector (1) from the A/C pressure transducer located on the A/C discharge line (3). 4. Remove the A/C pressure transducer from the fitting on the A/C discharge line and remove and discard the O-ring seal. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Removal > Page 769 Refrigerant Pressure Sensor / Switch: Service and Repair Installation INSTALLATION NOTE: Use only the specified O-ring as it is made of special material for R-134a. Use only refrigerant oil of the type required for the A/C compressor. NOTE: Typical A/C pressure transducer shown. 1. Lubricate a new rubber O-ring seal (4) with clean refrigerant oil and install it onto the discharge line fitting (3). 2. Install the A/C pressure transducer (2) onto the A/C discharge line. Tighten the A/C pressure transducer securely. 3. Connect the wire harness connector (1) to the A/C pressure transducer. 4. Reinstall the top of the front fascia. 5. Reconnect the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Component ID: 348 Component : SWITCH-PARKING BRAKE Connector: Name : SWITCH-PARKING BRAKE Color : NATURAL # of pins : 1 Pin Description Circuit 1 PARK BRAKE SWITCH SENSE B25 20DG/WT Component Location - 35 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 774 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 775 Parking Brake Warning Switch: Diagrams Component ID: 348 Component : SWITCH-PARKING BRAKE Connector: Name : SWITCH-PARKING BRAKE Color : NATURAL # of pins : 1 Pin Description Circuit 1 PARK BRAKE SWITCH SENSE B25 20DG/WT Component Location - 35 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 776 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations Component ID: 338 Component : SWITCH-BACKUP LAMP Connector: Name : SWITCH-BACKUP LAMP Color : LT. GRAY # of pins : 2 Qualifier : (DIESEL) Pin Description Circuit 1 GROUND Z967 18BK/VT 2 BACKUP LAMP SWITCH SIGNAL T22 20YL/VT Component Location - 12 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 781 Connector: Name : SWITCH-BACKUP LAMP Color : GRAY # of pins : 2 Qualifier : (GAS MTX) A GROUND Z967 18BK/VT B BACKUP LAMP SWITCH SIGNAL T22 20YL/VT Component Location - 12 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 782 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 783 Backup Lamp Switch: Diagrams Component ID: 338 Component : SWITCH-BACKUP LAMP Connector: Name : SWITCH-BACKUP LAMP Color : LT. GRAY # of pins : 2 Qualifier : (DIESEL) Pin Description Circuit 1 GROUND Z967 18BK/VT 2 BACKUP LAMP SWITCH SIGNAL T22 20YL/VT Component Location - 12 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 784 Connector: Name : SWITCH-BACKUP LAMP Color : GRAY # of pins : 2 Qualifier : (GAS MTX) A GROUND Z967 18BK/VT B BACKUP LAMP SWITCH SIGNAL T22 20YL/VT Component Location - 12 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 785 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > BG6 Manual Transaxle Backup Lamp Switch: Service and Repair BG6 Manual Transaxle Removal REMOVAL 1. Disconnect battery negative cable. 2. Raise vehicle on hoist. 3. Disconnect backup lamp switch connector. 4. Remove backup lamp switch (1). Installation INSTALLATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > BG6 Manual Transaxle > Page 788 1. Install the backup lamp switch (1) with a new washer and tighten to 40 Nm (29 ft. lbs.). 2. Connect backup lamp switch connector. 3. Lower vehicle. 4. Connect battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > BG6 Manual Transaxle > Page 789 Backup Lamp Switch: Service and Repair T355 Manual Transaxle Removal REMOVAL 1. Lift vehicle on hoist. 2. From bottom side of vehicle, disconnect back-up lamp switch connector (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > BG6 Manual Transaxle > Page 790 3. Unscrew switch (2) from transaxle. Installation INSTALLATION Install back-up lamp switch (2). Teflon tape or equivalent must be used on switch threads. Tighten switch to 24 Nm (18 ft. lbs.). CAUTION: Do not overtighten switch. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > BG6 Manual Transaxle > Page 791 1. Connect back-up lamp switch connector (2). 2. Lower vehicle. 3. Verify back-up lamp operation. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations Component ID: 358 Component : SWITCH-STOP LAMP Connector: Name : SWITCH-STOP LAMP Color : BLACK # of pins : 6 Pin Description Circuit 1 FUSED B(+) A924 20DG/WT 2 STOP LAMP SWITCH OUTPUT L53 20DG/WT 3 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 4 BRAKE SIGNAL 2 B16 20LB/DG 5 GROUND Z967 18BK/VT 6 BRAKE SIGNAL 1 B15 20DG/WT Component Location - 44 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 795 Component Location - 47 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 796 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 797 Brake Light Switch: Diagrams Component ID: 358 Component : SWITCH-STOP LAMP Connector: Name : SWITCH-STOP LAMP Color : BLACK # of pins : 6 Pin Description Circuit 1 FUSED B(+) A924 20DG/WT 2 STOP LAMP SWITCH OUTPUT L53 20DG/WT 3 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 4 BRAKE SIGNAL 2 B16 20LB/DG 5 GROUND Z967 18BK/VT 6 BRAKE SIGNAL 1 B15 20DG/WT Component Location - 44 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 798 Component Location - 47 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 799 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Description Brake Light Switch: Description and Operation Description DESCRIPTION The stop lamp switch (3) is located under the instrument panel, at the brake pedal (2). It has three internal switches controlling various functions of the vehicle. It's main function is to control operation of the vehicle's brake lamps. Other functions include speed control deactivation, brake sense for the antilock brake system and brake sense for the brake transmission shift interlock. CAUTION: The switch can only be adjusted once. That is during initial installation of the switch. If the switch is not adjusted properly or has been removed for some service, a new switch must be installed and adjusted. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Description > Page 802 Brake Light Switch: Description and Operation Operation OPERATION When the brake pedal is pressed, the plunger on the outside of the stop lamp switch extends outward. This action opens or closes the contacts of the three switches inside the stop lamp switch. With the brake pedal pressed down (plunger extended), the switch for terminals 1 and 2 is closed completing the circuit. The switch for terminals 3 and 4 is open and so is the switch for 5 and 6. When the brake pedal is released (plunger pushed in), the three switches assume the opposite positions. The switch for terminals 1 and 2 is now open while the other two switches are now closed, completing their circuits. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 803 Brake Light Switch: Testing and Inspection STOP LAMP SWITCH NOTE: Before proceeding with this diagnostic test, verify the adjustment lever on the back of the switch is in the adjusted position. If the lever is in the non-adjusted (diagonal) position it may have never been adjusted. If the electrical circuit has been tested and the stop lamp switch is suspected of being damaged or inoperative, it can be tested using the following method. 1. Remove the switch from the vehicle. 2. With the switch in the released position (plunger extended), use an ohmmeter to test each of the three internal switches as shown. You should achieve the results as listed in the figure. 3. Gently push the plunger on the stop lamp switch in until it stops. 4. With the switch in this depressed position (plunger pushed in), use an ohmmeter to test each of the three internal switches as shown. You should achieve the results as listed in the figure. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 804 If you do not achieve the results as listed in both figures, the switch must be replaced. If the switch is found to be operating properly, it may be misadjusted. Do not reinstall the switch, replace it. CAUTION: The switch can only be adjusted once. That is during initial installation of the switch. If the switch is not adjusted properly or has been removed for any reason, a new switch must be installed and adjusted. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Removal Brake Light Switch: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable from its post on the battery. 2. If equipped, remove the silencer pad below the steering column. 3. Disconnect the wiring harness connector (4) at the switch (3). 4. Remove the stop lamp switch (2) from the brake pedal bracket (1) by rotating the switch in a counterclockwise direction approximately 30 degrees, then pulling the switch rearward. 5. Discard the stop lamp switch. It must not be reused. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Removal > Page 807 Brake Light Switch: Service and Repair Installation INSTALLATION CAUTION: Do not reuse the original stop lamp switch. The switch can only be adjusted once. That is during initial installation of the switch. If the switch is not adjusted properly or has been removed for some service, a new switch must be installed and adjusted. 1. Obtain a NEW stop lamp switch. The adjustment lever on the NEW switch should be at a 45° angle from the wiring connector. If the adjustment lever is parallel with the wiring connector, the switch has been pre-set and must be scrapped. DO NOT ATTEMPT TO RESET (OR RE-ADJUST) THE STOP LAMP SWITCH. 2. Mount and adjust the NEW brake lamp switch (2) using the following steps: a. Install the switch in its bracket by aligning the index tab on the switch with the notch in the brake pedal bracket (1). b. When the switch body is fully seated in its bracket, rotate the switch clockwise approximately 30° to lock the switch into place. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Removal > Page 808 c. With the brake pedal in the fully released position, move the adjustment lever on the brake lamp switch from the 45° angled non-adjusted position, clockwise as shown, until it is parallel with the wiring connector. The brake lamp switch is now properly adjusted to the vehicle. 3. Connect the wiring harness connector (4) to the switch (3). 4. If equipped, install the silencer pad below the steering column. 5. Reconnect the battery negative terminal. 6. Check the stop lamps to verify they are operating properly and not staying on when the pedal is in the released position. 7. Road test the vehicle to ensure proper operation of the brakes (including ABS) and speed control (if equipped). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Description Combination Switch: Description and Operation Description DESCRIPTION The left (lighting) multi-function switch is located on the left side of the steering column, just below the steering wheel. This switch is the primary control for the interior and exterior lighting systems. The only visible components of the switch are the control stalk (2), control knob (1) and control sleeve (3) that extend through the steering column shrouds on the left side of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator are concealed beneath the shrouds. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Description > Page 813 ERROR: undefined OFFENDING COMMAND: f‘~ STACK: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Description > Page 814 Combination Switch: Description and Operation Operation OPERATION The left (lighting) multi-function switch uses resistor multiplexing to control the many functions and features it provides using a minimal number of hard wired circuits. The switch then sends electronic switch status messages over the Local Interconnect Network (LIN) to the Cab Compartment Node (CCN) and then the CCN sends messages over the Controller Area Network (CAN) data bus to the Totally Integrated Power Module (TIPM) other electronic modules in the vehicle. For lighting and wiper function it sends the messages over the LIN bus to the CCN and the CCN puts them out on the CAN bus to the other modules. The left switch has the microprocessor for all communication to the TIPM. The SCCM is composed of a clockspring and left lighting switch and a right wiper switch. The TIPM, controls the lighting and wiper functions. The left multi-function switch can be diagnosed using LIN based diagnostic tools and methods. However, the most reliable, efficient and accurate means to diagnose this component requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. EXTERIOR LIGHTING Following are descriptions of how the left multi-function switch is operated to control the many exterior lighting functions and features it provides: - Front Fog Lamps - The optional front fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the front fog lamps to be selected while the headlamp On position is also selected, and will automatically move the control knob to the front fog lamps Off position when the control knob is rotated to deselect the headlamps. - Headlamps - The headlamps are requested when the left multi-function switch control knob is rotated to the headlamps on detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Headlamp Beam Selection - The headlamp beams are selected when the left multi-function switch control stalk is pushed forward. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. Each time the control stalk is actuated in this manner, the headlamp beams are toggled from the current selection to the opposite selection. - Headlamp Optical Horn - The headlamp optical horn is selected each time the left multi-function switch control stalk is pulled rearward to a momentary position just short of the beam selection detent position. The headlamp high beams will remain illuminated for as long as the control stalk is held in this momentary position and the previously selected beams will be restored when the control stalk is released. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Park Lamps - The headlamps are requested when the left multi-function switch control knob is rotated to the park lamps on detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Rear Fog Lamps - The optional rear fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position and then rotated to the rear fog lamps detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the rear fog lamps to be selected while the front fog lamps On position is also selected, and will automatically move the control knob to the rear fog lamp Off position when the control knob is pushed in to deselect the front fog lamps. - Turn Signal Control - The turn signals are requested when the left multi-function switch control stalk is moved downward (left signal) or upward (right signal). The control stalk has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary "lane change" position in each direction that provides turn signals only until the control stalk is released. When the control stalk is moved to a detent turn signal switch position, a cancel actuator extends toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring, rotates with the steering wheel and the cam lobes contact the cancel actuator when it is extended from the left multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the two turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the left turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral Off position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. INTERIOR LIGHTING Following are descriptions of the how the left multi-function switch is operated to control the many interior lighting functions and features it provides: - Interior Lamps Defeat - The interior lamps defeat feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps defeat detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Description > Page 815 CAN data bus to the other electronic modules in the vehicle. - Interior Lamps On - The interior lamps on feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps On detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Panel Lamps Dimming - The panel lamps dimming function is active only when the left multi-function switch control knob is in any exterior lighting On position. With the exterior lighting On, the panel lamps dimming level is requested when the left multi-function switch control sleeve is rotated to any one of five minor detent positions. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Parade Mode - The parade or funeral mode is active only when the left multi-function switch control knob is in any exterior lighting On position. With the exterior lighting On, the parade mode is requested when the left multi-function switch control sleeve is rotated to the parade mode detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair > Removal Combination Switch: Service and Repair Removal REMOVAL NOTE: It is not necessary to remove the Steering Column Control Module (SCCM) from the steering column to replace the left multi-function switch (2). 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the system reserve capacitor to discharge before servicing any airbag or steering column components. 2. Remove both the upper and lower shrouds from the steering column. 3. Remove the one screw (2) that secures the left multi-function switch (3) on the right side of the clockspring (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair > Removal > Page 818 4. Pull the switch (2) straight away from the clockspring (1) far enough to access the electrical connector (3) to disconnect it. 5. Disconnect the instrument panel wiring harness from the back of the left multi-function switch. 6. Remove the switch (2) from the clockspring (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair > Removal > Page 819 Combination Switch: Service and Repair Installation INSTALLATION 1. Position the left multi-function switch in the slot in the back of the clockspring (1) and connect the switch connector (3). 2. Connect the instrument panel wiring harness connector to the back of the left multi-function switch. 3. Align switch (3) with the clockspring (1) and slide toward steering column. 4. Install the screw (2) that secures the switch (3) to the clockspring (1). 5. Install the upper and lower shrouds onto the steering column. 6. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Description and Operation > Description Hazard Warning Switch: Description and Operation Description DESCRIPTION The hazard switch is located in the Accessory Switch Bank Module (ASBM) just below the heater a/c controls, in the instrument panel center stack. This switch is the control for the hazard warning lighting. The only visible component of the switch is the control push button that is located just to the left of the Passenger Airbag Disabled Light (PADL) indicator. On BUX models, the hazard switch is located to the left of the Headlamp Leveling Switch, in the ASBM. The hazard switch cannot be adjusted or repaired. If the switch is ineffective or damaged, the entire ASBM must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Description and Operation > Description > Page 824 Hazard Warning Switch: Description and Operation Operation OPERATION The hazard switch features a push-push type latching push button. When the push button is in its latched (lowered) position the switch contacts are open, and when the push button is in its unlatched (raised) position the switch contacts are closed. The hazard switch receives a ground on one terminal and provides a ground signal output to the Totally Integrated Power Module (TIPM) ) whenever the switch contacts are closed. The TIPM responds to this input by controlling a battery voltage output and the flash rate for each of the right and left turn signal lamps, then sends an electronic hazard switch status message over the Controller Area Network (CAN) data bus to the Electromechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) to control the illumination and flash rate of the right and left turn signal indicators, as well as to control the click rate of an electromechanical relay soldered onto the EMIC electronic circuit board that emulates the sound emitted by a conventional hazard warning flasher. The hazard switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations Horn Switch: Locations Component ID: 344 Component : SWITCH-HORN Connector: Name : SWITCH-HORN Color : BLACK # of pins : 2 Pin Description Circuit 1 HORN SWITCH SENSE X3 20DB 2 RADIO CONTROL RETURN Y13 20BK Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 828 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 829 Horn Switch: Diagrams Component ID: 344 Component : SWITCH-HORN Connector: Name : SWITCH-HORN Color : BLACK # of pins : 2 Pin Description Circuit 1 HORN SWITCH SENSE X3 20DB 2 RADIO CONTROL RETURN Y13 20BK Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 830 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Description and Operation > Description Horn Switch: Description and Operation Description DESCRIPTION WARNING: On vehicles equipped with an airbag, refer to restraint systems for warnings and cautions before servicing the horn switch. The horn switch is mounted inside the driver airbag. The horn switch has three contacts that are grounded when the driver airbag is depressed. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Description and Operation > Description > Page 833 Horn Switch: Description and Operation Operation OPERATION When the Driver Airbag Cover is pressed, the horn switch makes contact to ground. The ground signal is carried to the horn relay and the horn sounds. The horn switch grounds to the airbag housing. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service and Repair > Removal Horn Switch: Service and Repair Removal REMOVAL WARNING: On vehicles equipped with an airbag, refer to restraint systems for warnings and cautions before servicing the horn switch. 1. Disconnect and isolate the battery negative cable. 2. Remove the driver airbag. 3. Disconnect the connector from the clockspring. 4. Remove the three mounting fasteners. 5. Remove the horn switch. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service and Repair > Removal > Page 836 Horn Switch: Service and Repair Installation INSTALLATION 1. Install the horn switch. 2. Install the three mounting fasteners. 3. Connect the electrical connector to the clockspring. 4. Install the driver airbag. 5. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Component ID: 281 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 APP SIGNAL 2 K29 20WT/BR 2 APP SENSOR GROUND 2 K400 20BR/VT 3 5 VOLT SUPPLY K854 20VT/BR 3 5 VOLT SUPPLY K858 20BR/GY 4 APP SIGNAL 1 K23 20BR/OR 5 APP SENSOR GROUND 1 K167 20BR/YL 6 5 VOLT SUPPLY K852 20BR/VT 6 5 VOLT SUPPLY F856 20YL/PK Component Location - 44 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 842 Component Location - 47 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 843 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 844 Accelerator Pedal Position Sensor: Diagrams Component ID: 281 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 APP SIGNAL 2 K29 20WT/BR 2 APP SENSOR GROUND 2 K400 20BR/VT 3 5 VOLT SUPPLY K854 20VT/BR 3 5 VOLT SUPPLY K858 20BR/GY 4 APP SIGNAL 1 K23 20BR/OR 5 APP SENSOR GROUND 1 K167 20BR/YL 6 5 VOLT SUPPLY K852 20BR/VT 6 5 VOLT SUPPLY F856 20YL/PK Component Location - 44 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 845 Component Location - 47 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 846 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 847 Accelerator Pedal Position Sensor: Description and Operation DESCRIPTION The Accelerator Pedal Position Sensor (APPS) is a variable resistor that provides the PCM with an input signal (voltage). The signal represents pedal angle position. As the position of the accelerator pedal changes, the resistance of the APPS changes. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal Accelerator Pedal Position Sensor: Service and Repair Removal REMOVAL 1. Disconnect negative battery cable. 2. Disconnect the electrical connector from the module. 3. Remove the mounting nuts. 4. Remove assembly from the mounting studs. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal > Page 850 Accelerator Pedal Position Sensor: Service and Repair Installation INSTALLATION 1. Install APPS module. 2. Tighten the mounting nuts. 3. Connect electrical connector. 4. Connect negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Sensor-Camshaft 1/1 Position Camshaft Position Sensor: Locations Sensor-Camshaft 1/1 Position Component ID: 284 Component : SENSOR-CAMSHAFT 1/1 POSITION Connector: Name : SENSOR-CAMSHAFT 1/1 POSITION Color : BLACK # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY K857 20BR/LG 2 SENSOR GROUND K900 20DB/DG 3 CMP 1/1 SIGNAL K44 20DB Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Sensor-Camshaft 1/1 Position > Page 855 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Sensor-Camshaft 1/1 Position > Page 856 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Sensor-Camshaft 1/1 Position > Page 857 Camshaft Position Sensor: Locations Sensor-Camshaft 1/2 Position Component ID: 285 Component : SENSOR-CAMSHAFT 1/2 POSITION Connector: Name : SENSOR-CAMSHAFT 1/2 POSITION Color : BLACK # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K915 20BR/WT 3 CMP 1/2 SIGNAL K441 20DB/BR Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Sensor-Camshaft 1/1 Position > Page 858 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Sensor-Camshaft 1/1 Position Camshaft Position Sensor: Diagrams Sensor-Camshaft 1/1 Position Component ID: 284 Component : SENSOR-CAMSHAFT 1/1 POSITION Connector: Name : SENSOR-CAMSHAFT 1/1 POSITION Color : BLACK # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY K857 20BR/LG 2 SENSOR GROUND K900 20DB/DG 3 CMP 1/1 SIGNAL K44 20DB Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Sensor-Camshaft 1/1 Position > Page 861 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Sensor-Camshaft 1/1 Position > Page 862 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Sensor-Camshaft 1/1 Position > Page 863 Camshaft Position Sensor: Diagrams Sensor-Camshaft 1/2 Position Component ID: 285 Component : SENSOR-CAMSHAFT 1/2 POSITION Connector: Name : SENSOR-CAMSHAFT 1/2 POSITION Color : BLACK # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K915 20BR/WT 3 CMP 1/2 SIGNAL K441 20DB/BR Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Sensor-Camshaft 1/1 Position > Page 864 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Description Camshaft Position Sensor: Description and Operation Description DESCRIPTION The camshaft position sensors are mounted to the front and rear of the cylinder head. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Description > Page 867 Camshaft Position Sensor: Description and Operation Operation OPERATION The PCM sends approximately 5 volts to the Hall-effect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. The input to the PCM occurs on a 5 volt output reference circuit. A ground for the sensor is provided through the sensor return circuit. The PCM identifies camshaft position by registering the change from 5 to 0 volts, as signaled from the camshaft position sensor. The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Removal Camshaft Position Sensor: Service and Repair Removal Front Camshaft Position Sensor FRONT CAMSHAFT POSITION SENSOR 1. Remove the air cleaner hose to throttle body, disconnect the inlet air temperature sensor electrical connector. 2. Disconnect negative battery cable. 3. Disconnect electrical connector from camshaft position sensor. 4. Remove camshaft position sensor mounting screws. 5. Remove sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 870 Rear Camshaft Position Sensor REAR CAMSHAFT POSITION SENSOR 1. Disconnect negative battery cable. 2. Disconnect electrical connector at sensor. 3. Remove nut retaining heat shield. 4. Pull heat shield out to uncover sensor. 5. Remove mounting bolt. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 871 6. Remove sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 872 Camshaft Position Sensor: Service and Repair Installation Front Camshaft Position Sensor FRONT CAMSHAFT POSITION SENSOR 1. Lubricate sensor O-ring. 2. Install camshaft position sensor utilizing twisting motion. Make sure sensor is fully seated. Do not drive sensor into the bore with screw. This can cause sensor to be incorrectly seated causing engine to fail. Tighten sensor mounting screws to 9 Nm (79.5 in. lbs.). 3. Carefully attach electrical connector to camshaft position sensor. Installation at an angle may damage the sensor pins. 4. Install the negative battery cable. 5. Install the air cleaner to throttle body hose, connect the inlet air temperature sensor electrical connector. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 873 Rear Camshaft Position Sensor REAR CAMSHAFT POSITION SENSOR 1. Lubricate sensor O-ring. 2. Install sensor utilizing twisting motion. Make sure sensor is fully seated. Do not drive sensor into the bore with screw. This can cause sensor to be incorrectly seated causing engine to fail. 3. Install mounting bolt and tighten to 9 Nm (79.5 in. lbs.). 4. Carefully attach electrical connector to camshaft position sensor. Fill for positive lock (click). Installation at angle may damage the sensor pins. 5. Install heat shield onto mounting stud. 6. Install heat shield retaining nut and tighten. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 874 7. Connect the electrical connector. 8. Connect negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor Coolant Temperature Sensor/Switch (For Computer): Technical Service Bulletins Engine Controls MIL On/DTC P0116/ECT Sensor NUMBER: 18-039-06 GROUP: Vehicle Performance DATE: December 6, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES FOR StarSCAN. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 7.02 SP2 OR HIGHER FOR THIS BULLETIN. SUBJECT: Flash: MIL Illumination DTC P0116 - Engine Coolant Temperature Sensor Performance OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) and the Transmission Control Module (1CM) with new software. CAUTION: VEHICLES EQUIPPED WITH A CVT TRANSMISSION MUST HAVE THE TRANSMISSION CONTROL MODULE (TCM) CHECKED FOR THE LATEST SOFTWARE LEVEL WHENEVER THE PCM SOFTWARE IS UPGRADED. IF NEWER TCM SOFTWARE IS AVAILABLE, IT MUST BE INSTALLED. MODELS: 2007 (PM) Caliber 2007 (MK49) Compass NOTE: This bulletin applies to PM/MK models equipped with a 1.8L, 2.0L or 2.4L gasoline engine (Sales Code EBA, ECN or ED3) and block heater (Sales Code NHK) built before November 20, 2006 (MDH 1120XX). NOTE: If an aftermarket or MOPAR accessory block heater is installed, the same conditions may apply. SYMPTOM/CONDITION: Some customers may experience MIL illumination after using the block heater. No other symptoms will be experienced. The technician may find the following DTC's: ^ P0116 - ENGINE COOLANT TEMPERATURE SENSOR PERFORMANCE DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If MIL illumination with DTC P0116 is present, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 879 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING **STEP 5n and/or 8h**. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 7.02 SP2 software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. PM/MK Models equipped with a CVT must have the TCM reprogrammed as follows: 6. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. 7. Is the TCM part number recorded in step 6e above, the same as the new p/n shown on the "Flash File List" screen? a. Yes >> No further action is necessary. Proceed to Step 9. b. No >> the TCM will require flash reprogramming, proceed to Step 8. 8. Flash reprogram the TCM as follows: a. From the "Flash File List" screen, select "Download to Scantool". b. Select "Close" after the download is complete, then select "Back". c. Highlight the listed calibration. d. Select "Update Controller". Follow on screen instructions. e. When the update is complete, select "OK". f. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. g. Turn the ignition switch to the OFF position for no less than 15 seconds. h. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 880 CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the TCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. ** NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 9. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Sensor-Engine Coolant Temperature 1 Coolant Temperature Sensor/Switch (For Computer): Locations Sensor-Engine Coolant Temperature 1 Component ID: 290 Component : SENSOR-ENGINE COOLANT TEMPERATURE 1 Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE 1 Color : DK. GRAY # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 SENSOR GROUND K900 20DB/DG 2 ECT 1 SIGNAL K2 20VT/OR Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Sensor-Engine Coolant Temperature 1 > Page 883 Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Sensor-Engine Coolant Temperature 1 > Page 884 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Sensor-Engine Coolant Temperature 1 > Page 885 Coolant Temperature Sensor/Switch (For Computer): Locations Sensor-Engine Coolant Temperature 2 Component ID: 291 Component : SENSOR-ENGINE COOLANT TEMPERATURE 2 Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE 2 Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 SENSOR GROUND K915 20BR/WT 2 ECT 2 SIGNAL K222 20BR/YL Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Sensor-Engine Coolant Temperature 1 > Page 886 Component Location - 15 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Sensor-Engine Coolant Temperature 1 > Page 887 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Sensor-Engine Coolant Temperature 1 Coolant Temperature Sensor/Switch (For Computer): Diagrams Sensor-Engine Coolant Temperature 1 Component ID: 290 Component : SENSOR-ENGINE COOLANT TEMPERATURE 1 Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE 1 Color : DK. GRAY # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 SENSOR GROUND K900 20DB/DG 2 ECT 1 SIGNAL K2 20VT/OR Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Sensor-Engine Coolant Temperature 1 > Page 890 Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Sensor-Engine Coolant Temperature 1 > Page 891 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Sensor-Engine Coolant Temperature 1 > Page 892 Coolant Temperature Sensor/Switch (For Computer): Diagrams Sensor-Engine Coolant Temperature 2 Component ID: 291 Component : SENSOR-ENGINE COOLANT TEMPERATURE 2 Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE 2 Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 SENSOR GROUND K915 20BR/WT 2 ECT 2 SIGNAL K222 20BR/YL Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Sensor-Engine Coolant Temperature 1 > Page 893 Component Location - 15 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Sensor-Engine Coolant Temperature 1 > Page 894 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Component ID: 287 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 CKP SENSOR 5 VOLT SUPPLY K853 20DB/BR 2 CKP SENSOR SIGNAL K24 20BR/LB 3 CKP SENSOR GROUND K925 20DB/WT Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 898 Component Location - 19 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 899 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 900 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20LB/BR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 901 Component Location - 16 Component Location - 19 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 902 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 903 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 904 Crankshaft Position Sensor: Diagrams Component ID: 287 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 CKP SENSOR 5 VOLT SUPPLY K853 20DB/BR 2 CKP SENSOR SIGNAL K24 20BR/LB 3 CKP SENSOR GROUND K925 20DB/WT Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 905 Component Location - 19 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 906 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 907 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20LB/BR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 908 Component Location - 16 Component Location - 19 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 909 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 910 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description DESCRIPTION The crankshaft position sensor mounts to the rear of the engine block near the transmission. The PCM uses the Crankshaft Position sensor to calculate the following: - Engine RPM - TDC number 1 and 4 - Ignition coil synchronization - Injector synchronization - Camshaft-to-crankshaft misalignment (Timing belt skipped 1 tooth or more diagnostic trouble code). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 913 Crankshaft Position Sensor: Description and Operation Operation OPERATION The PCM sends approximately 5 volts to the Hall-effect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. A ground for the sensor is provided through the sensor return circuit. The input to the PCM occurs on a 5 volt output reference circuit that operates as follows: The Hall-effect sensor contains a powerful magnet. As the magnetic field passes over the dense portion of the counterweight, the 5-volt signal is pulled to ground (0.3 volts) through a transistor in the sensor. When the magnetic field passes over the notches in the crankshaft counterweight, the magnetic field turns off the transistor in the sensor, causing the PCM to register the 5-volt signal. The PCM identifies crankshaft position by registering the change from 5 to 0 volts, as signaled from the Crankshaft Position sensor (2). The PCM determines which cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. The #8 crankshaft counterweight has a target ring with 32 teeth and notches (1), including one long reference tooth and notch. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Removal Crankshaft Position Sensor: Service and Repair Removal 2.0/2.4L The Crankshaft Position Sensor is in the rear of the engine block near the transmission. If vehicle is All Wheel Drive the Power Transfer Unit must be removed. 1. Disconnect the negative battery cable. 2. Raise vehicle and support. 3. Remove heat shield retaining bolt. 4. Remove heat shield. 5. Unlock and disconnect the electrical connector to the crankshaft position sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Removal > Page 916 6. Remove the crankshaft position sensor bolt. 7. Remove the sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Removal > Page 917 Crankshaft Position Sensor: Service and Repair Installation 2.0/2.4L 1. Check O-ring for damage and lubricate the O-ring with engine oil before installing sensor. 2. Use a twisting motion when installing the sensor. 3. Install and tighten the crankshaft position sensor bolt and tighten to 9 Nm (79.5 in. lbs.). 4. Connect and lock the electrical connector to the crankshaft position sensor. 5. Install heat shield and retaining bolt. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Removal > Page 918 If vehicle is All Wheel Drive the Power Transfer Unit must be installed. 6. Lower vehicle. 7. Connect the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations Component ID: 297 Component : SENSOR-INTAKE AIR TEMPERATURE Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 IAT SIGNAL K21 20BK/RD 2 SENSOR GROUND K915 20BR/WT Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 922 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 923 Intake Air Temperature Sensor: Diagrams Component ID: 297 Component : SENSOR-INTAKE AIR TEMPERATURE Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 IAT SIGNAL K21 20BK/RD 2 SENSOR GROUND K915 20BR/WT Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 924 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 925 Intake Air Temperature Sensor: Description and Operation DESCRIPTION The IAT Sensor is a Negative Temperature Coefficient (NTC) Sensor that provides information to the PCM regarding the temperature of the air entering the intake manifold. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Removal Intake Air Temperature Sensor: Service and Repair Removal 2.0/2.4L The sensor is located in the clean air duct. 1. Disconnect the negative battery cable. 2. Disconnect electrical connector from the sensor. 3. Remove the sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Removal > Page 928 Intake Air Temperature Sensor: Service and Repair Installation 2.0/2.4L The sensor is in the clean air duct. 1. Install sensor. Make sure of sensor orientation. 2. Attach electrical connector to sensor. 3. Connect the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Component ID: 299 Component : SENSOR-KNOCK Connector: Name : SENSOR-KNOCK Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 KS SIGNAL K42 20LG/DB 2 KS RETURN K942 20WT/BR Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 932 Component Location - 15 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 933 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 934 Knock Sensor: Diagrams Component ID: 299 Component : SENSOR-KNOCK Connector: Name : SENSOR-KNOCK Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 KS SIGNAL K42 20LG/DB 2 KS RETURN K942 20WT/BR Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 935 Component Location - 15 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 936 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Description Knock Sensor: Description and Operation Description DESCRIPTION The knock sensor is bolted to the cylinder block. The knock sensor is designed to detect engine vibration that is caused by detonation or preignition. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Description > Page 939 Knock Sensor: Description and Operation Operation OPERATION When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives as an input the knock sensor voltage signal. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, ignition timing retard is allowed. Ignition timing is retarded uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard ignition timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except WOT. The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening affects knock sensor performance, possibly causing improper spark control. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Removal Knock Sensor: Service and Repair Removal 2.0/2.4L The knock sensor bolts into the side of the cylinder block in front of the starter under the intake manifold. 1. Disconnect the negative battery cable. 2. Remove the bolt holding the knock sensor. 3. Remove sensor with electrical connector attached. 4. Disconnect electrical connector from knock sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Removal > Page 942 5. Remove the knock sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Removal > Page 943 Knock Sensor: Service and Repair Installation 2.0/2.4L The knock sensor bolts into the side of the cylinder block in front of the starter under the intake manifold. 1. Attach electrical connector to knock sensor. 2. Install knock sensor. Tighten knock sensor bolt to 22 Nm (195 in. lbs.). Over or under tightening effects knock sensor performance, possibly causing improper spark control. 3. Connect the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations Component ID: 300 Component : SENSOR-MAP Connector: Name : SENSOR-MAP Color : BLACK # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 MAP SIGNAL K1 20VT/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY K857 20BR/LG Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 947 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 948 Manifold Pressure/Vacuum Sensor: Diagrams Component ID: 300 Component : SENSOR-MAP Connector: Name : SENSOR-MAP Color : BLACK # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 MAP SIGNAL K1 20VT/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY K857 20BR/LG Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 949 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Description Manifold Pressure/Vacuum Sensor: Description and Operation Description DESCRIPTION The MAP sensor mounts to the intake manifold. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Description > Page 952 Manifold Pressure/Vacuum Sensor: Description and Operation Operation OPERATION The MAP serves as a PCM input, using a silicon based sensing unit, to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When MAP equals Barometric pressure, the pulse width will be at maximum. Also like the cam and crank sensors, a 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5 volt and full scale is 4.5 volt. For a pressure swing of 0 - 15 psi the voltage changes 4.0 volt. The sensor is supplied a regulated 4.8 to 5.1 volts to operate the sensor. Like the cam and crank sensors ground is provided through the sensor return circuit. The MAP sensor input is the number one contributor to pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or is it in Denver at 5000 feet above sea level, because the air density changes with altitude. It will also help to correct for varying weather conditions. If a hurricane was coming through the pressure would be very, very low or there could be a real fair weather, high pressure area. This is important because as air pressure changes the barometric pressure changes. Barometric pressure and altitude have a direct inverse correlation, as altitude goes up barometric goes down. The first thing that happens as the key is rolled on, before reaching the crank position, the PCM powers up, comes around and looks at the MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure relative to altitude. Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key on. The difference between current and what it was at key on is manifold vacuum. During key On (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring known good sensor in your work area. As the altitude increases the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key On the barometric pressure needs to be updated. Any time the PCM sees Wide Open throttle, based upon TPS angle and RPM it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively. The PCM uses the MAP sensor to aid in calculating the following: - Barometric pressure - Engine load - Manifold pressure - Injector pulse-width - Spark-advance programs - Shift-point strategies (F4AC1 transmissions only, via the PCI bus) - Idle speed - Decel fuel shutoff The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 88 kPa (26 in. Hg). Barometric pressure is the pressure exerted by the atmosphere upon an object. At sea level on a standard day, no storm, barometric pressure is 101 kPa (29.92 in. Hg). For every 30.5 meters (100 feet) of altitude barometric pressure drops .33 kPa (0.10 in. Hg). If a storm goes through it can either add, high pressure, or decrease, low pressure, from what should be present for that altitude. You should make a habit of knowing what the average pressure and corresponding barometric pressure is for your area. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal Manifold Pressure/Vacuum Sensor: Service and Repair Removal 2.0/2.4L 1. Remove the air cleaner cover. 2. Disconnect the negative battery cable. 3. Disconnect the electrical connector from the MAP sensor. 4. Remove the screws from the MAP sensor. 5. Remove the MAP sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 955 Manifold Pressure/Vacuum Sensor: Service and Repair Installation 2.0/2.4L 1. Make sure that the manifold is clean. 2. Install sensor to manifold. 3. Tighten screw. 4. Connect the electrical connector to the sensor. 5. Connect the negative battery cable. 6. Install the air cleaner cover. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 Oxygen Sensor: Locations Sensor - Oxygen 1/1 Component ID: 304 Component : SENSOR-OXYGEN 1/1 Connector: Name : SENSOR-OXYGEN 1/1 Color : GRAY # of pins : 4 Qualifier : (GAS) Pin Description Circuit 1 GROUND Z916 18BK 2 O2 1/1 HEATER CONTROL K99 20BR/OR 3 O2 1/1 RETURN K902 20BR/DG 4 O2 1/1 SIGNAL K41 20BK/DG Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 960 Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 961 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 962 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 963 Oxygen Sensor: Locations Sensor - Oxygen 1/2 Component ID: 305 Component : SENSOR-OXYGEN 1/2 Connector: Name : SENSOR-OXYGEN 1/2 Color : BLACK # of pins : 4 Qualifier : (GAS) Pin Description Circuit 1 GROUND Z924 18BK/LB 2 O2 1/2 HEATER CONTROL K299 20BR/RD 3 O2 1/2 RETURN K904 20DB/DG 4 O2 1/2 SIGNAL K141 20DB/YL Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 964 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 965 Oxygen Sensor: Locations 1/1 Upstream - 2.0/2.4L The upstream oxygen sensor threads into the outlet flange of the exhaust manifold. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 966 Oxygen Sensor: Locations 1/2 Downstream - 2.0/2.4L The downstream heated oxygen sensor threads into the catalytic converter. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Sensor-Oxygen 1/1 Oxygen Sensor: Diagrams Sensor-Oxygen 1/1 Component ID: 304 Component : SENSOR-OXYGEN 1/1 Connector: Name : SENSOR-OXYGEN 1/1 Color : GRAY # of pins : 4 Qualifier : (GAS) Pin Description Circuit 1 GROUND Z916 18BK 2 O2 1/1 HEATER CONTROL K99 20BR/OR 3 O2 1/1 RETURN K902 20BR/DG 4 O2 1/1 SIGNAL K41 20BK/DG Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Sensor-Oxygen 1/1 > Page 969 Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Sensor-Oxygen 1/1 > Page 970 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Sensor-Oxygen 1/1 > Page 971 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Sensor-Oxygen 1/1 > Page 972 Oxygen Sensor: Diagrams Sensor-Oxygen 1/2 Component ID: 305 Component : SENSOR-OXYGEN 1/2 Connector: Name : SENSOR-OXYGEN 1/2 Color : BLACK # of pins : 4 Qualifier : (GAS) Pin Description Circuit 1 GROUND Z924 18BK/LB 2 O2 1/2 HEATER CONTROL K299 20BR/RD 3 O2 1/2 RETURN K904 20DB/DG 4 O2 1/2 SIGNAL K141 20DB/YL Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Sensor-Oxygen 1/1 > Page 973 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 974 Oxygen Sensor: Application and ID - Cylinder bank number one is the bank that contains number one cylinder. See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description Oxygen Sensor: Description and Operation Description DESCRIPTION The upstream oxygen sensor threads into the outlet flange of the exhaust manifold. The downstream heated oxygen sensor threads into the system depending on emission package. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description > Page 977 Oxygen Sensor: Description and Operation Operation OPERATION Separate upstream and downstream grounds are used on the NGC vehicles (4 Cyl.). As vehicles accumulate mileage, the catalytic convertor deteriorates. The deterioration results in a less efficient catalyst. To monitor catalytic convertor deterioration, the fuel injection system uses two heated oxygen sensors. One sensor upstream of the catalytic convertor, one downstream of the convertor. The PCM compares the reading from the sensors to calculate the catalytic convertor oxygen storage capacity and converter efficiency. Also, the PCM uses the upstream heated oxygen sensor input when adjusting injector pulse width. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the malfunction indicator lamp (MIL). The O2 sensors produce a constant 2.5 volts on NGC vehicles, depending upon the oxygen content of the exhaust gas. When a large amount of oxygen is present (caused by a lean air/fuel mixture, can be caused by misfire and exhaust leaks), the sensors produce a low voltage. When there is a lesser amount of oxygen present (caused by a rich air/fuel mixture, which can be caused by internal engine problems) it produces a higher voltage. By monitoring the oxygen content and converting it to electrical voltage, the sensors act as a rich-lean switch. The oxygen sensors are equipped with a heating element that keeps the sensors at proper operating temperature during all operating modes. Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop operation the PCM monitors the O2 sensor's input (along with other inputs) and adjusts the injector pulse width accordingly. During Open Loop operation the PCM ignores the O2 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. The NGC Controller has a common ground for the heater in the O2S. 12 volts is supplied to the heater in the O2S by the NGC controller. Both the upstream and downstream O2 sensors for NGC are pulse width modulation (PWM). NOTE: When replacing an O2 Sensor, the PCM RAM memory must be cleared, either by disconnecting the PCM C-1 connector or momentarily disconnecting the Battery negative terminal. The NGC learns the characteristics of each O2 heater element and these old values should be cleared when installing a new O2 sensor. The customer may experience driveability issues if this is not performed. UPSTREAM OXYGEN SENSOR The input from the upstream heated oxygen sensor tells the PCM the oxygen content of the exhaust gas. Based on this input, the PCM fine tunes the air-fuel ratio by adjusting injector pulse width. The sensor input switches from 2.5 to 3.5 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air-fuel mixture), the sensor produces voltage as low as 2.5 volt. When there is a lesser amount of oxygen present (rich air-fuel mixture) the sensor produces a voltage as high as 3.5 volt. By monitoring the oxygen content and converting it to electrical voltage, the sensor acts as a rich-lean switch. The heating element in the sensor provides heat to the sensor ceramic element. Heating the sensor allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop, the PCM adjusts injector pulse width based on the upstream heated oxygen sensor input along with other inputs. In Open Loop, the PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. DOWNSTREAM OXYGEN SENSOR The downstream heated oxygen sensor input is used to detect catalytic convertor deterioration. As the convertor deteriorates, the input from the downstream sensor begins to match the upstream sensor input except for a slight time delay. By comparing the downstream heated oxygen sensor input to the input from the upstream sensor, the PCM calculates catalytic convertor efficiency. This is also used to establish the upstream O2 goal voltage (switching point). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal Oxygen Sensor: Service and Repair Removal 1/1 Upstream - 2.0/2.4L 1/1 UPSTREAM - 2.0/2.4L 1. Remove the engine cover. 2. Remove the negative battery cable. 3. Disconnect electrical connector from O2 sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 980 4. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent. 1/2 Downstream - 2.0/2.4L 1/2 DOWNSTREAM - 2.0/2.4L Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 981 The downstream heated oxygen sensor threads into the catalytic converter. 1. Remove the negative battery cable. 2. Raise vehicle and support. 3. Disconnect electrical connector from sensor. 4. Disconnect sensor electrical harness from clips along body. 5. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 982 Oxygen Sensor: Service and Repair Installation 1/1 Upstream - 2.0/2.4L 1/1 UPSTREAM - 2.0/2.4L 1. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite(R) 771-64 or equivalent. New sensors have compound on the threads and do not require an additional coating. Tighten the sensor to 41 Nm (30 ft. lbs.). 2. Install sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 983 3. Connect electrical connector to sensor. 4. Install the negative battery cable. 5. Install the engine cover. 1/2 Downstream - 2.0/2.4L 1/2 DOWNSTREAM - 2.0/2.4L Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 984 The downstream heated oxygen sensor threads into the exhaust pipe behind the catalytic converter. 1. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite(R) 771-64 or equivalent. New sensors have compound on the threads and do not require an additional coating. Tighten the sensor to 41 Nm (30 ft. lbs.). 2. Install sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent. 3. Connect sensor electrical harness to clips along body. 4. Connect electrical connector to sensor. 5. Lower vehicle. 6. Install the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Page 985 Oxygen Sensor: Tools and Equipment FUEL O2S (Oxygen Sensor) Remover/Installer-C-4907 O2S (Oxygen Sensor) Remover/Installer - 8439 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations Component ID: 318 Component : SENSOR-VEHICLE SPEED Connector: Name : SENSOR-VEHICLE SPEED Color : BLACK # of pins : 3 Qualifier : (GAS MTX) Pin Description Circuit 1 5 VOLT SUPPLY F856 20YL/PK 2 SENSOR GROUND K914 18BR/WT 3 VEHICLE SPEED SIGNAL K75 18WT/OR Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 989 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: Provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 992 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 993 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 994 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 995 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 996 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 997 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 998 5. Release the Secondary Terminal Lock, if required (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 999 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1000 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1001 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1002 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1003 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1004 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1005 Vehicle Speed Sensor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1006 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1007 STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1008 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1009 Vehicle Speed Sensor: Connector Views Component ID: 318 Component : SENSOR-VEHICLE SPEED Connector: Name : SENSOR-VEHICLE SPEED Color : BLACK # of pins : 3 Qualifier : (GAS MTX) Pin Description Circuit 1 5 VOLT SUPPLY F856 20YL/PK 2 SENSOR GROUND K914 18BR/WT 3 VEHICLE SPEED SIGNAL K75 18WT/OR Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1010 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Component ID: 281 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 APP SIGNAL 2 K29 20WT/BR 2 APP SENSOR GROUND 2 K400 20BR/VT 3 5 VOLT SUPPLY K854 20VT/BR 3 5 VOLT SUPPLY K858 20BR/GY 4 APP SIGNAL 1 K23 20BR/OR 5 APP SENSOR GROUND 1 K167 20BR/YL 6 5 VOLT SUPPLY K852 20BR/VT 6 5 VOLT SUPPLY F856 20YL/PK Component Location - 44 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1015 Component Location - 47 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1016 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1017 Accelerator Pedal Position Sensor: Diagrams Component ID: 281 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 APP SIGNAL 2 K29 20WT/BR 2 APP SENSOR GROUND 2 K400 20BR/VT 3 5 VOLT SUPPLY K854 20VT/BR 3 5 VOLT SUPPLY K858 20BR/GY 4 APP SIGNAL 1 K23 20BR/OR 5 APP SENSOR GROUND 1 K167 20BR/YL 6 5 VOLT SUPPLY K852 20BR/VT 6 5 VOLT SUPPLY F856 20YL/PK Component Location - 44 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1018 Component Location - 47 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1019 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1020 Accelerator Pedal Position Sensor: Description and Operation DESCRIPTION The Accelerator Pedal Position Sensor (APPS) is a variable resistor that provides the PCM with an input signal (voltage). The signal represents pedal angle position. As the position of the accelerator pedal changes, the resistance of the APPS changes. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal Accelerator Pedal Position Sensor: Service and Repair Removal REMOVAL 1. Disconnect negative battery cable. 2. Disconnect the electrical connector from the module. 3. Remove the mounting nuts. 4. Remove assembly from the mounting studs. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal > Page 1023 Accelerator Pedal Position Sensor: Service and Repair Installation INSTALLATION 1. Install APPS module. 2. Tighten the mounting nuts. 3. Connect electrical connector. 4. Connect negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Description and Operation Turbo Boost Sensor: Description and Operation DESCRIPTION Turbocharged vehicles are equipped with three solenoids that are PCM controlled. They are mounted to the right shock tower. A vacuum harness connects the solenoids to their respective component. - Wastegate Actuator Solenoid - Surge Valve Actuator Solenoid - Throttle Inlet Pressure (TIP) Solenoid Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Service and Repair > Removal Turbo Boost Sensor: Service and Repair Removal REMOVAL 1. Remove nuts (1) securing solenoid mounting bracket to shock tower. 2. Disconnect solenoid electrical connector. 3. Disconnect vacuum harness connector from solenoid. 4. Push on solenoid lock tab (1) and slide solenoid off bracket. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Service and Repair > Removal > Page 1029 Turbo Boost Sensor: Service and Repair Installation INSTALLATION 1. Slide solenoid onto mounting bracket until lock tab engages. 2. Connect vacuum harness connector to solenoid. 3. Connect solenoid electrical connector. 4. Install nuts securing solenoid mounting bracket to shock tower. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Sensor-Camshaft 1/1 Position Camshaft Position Sensor: Locations Sensor-Camshaft 1/1 Position Component ID: 284 Component : SENSOR-CAMSHAFT 1/1 POSITION Connector: Name : SENSOR-CAMSHAFT 1/1 POSITION Color : BLACK # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY K857 20BR/LG 2 SENSOR GROUND K900 20DB/DG 3 CMP 1/1 SIGNAL K44 20DB Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Sensor-Camshaft 1/1 Position > Page 1035 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Sensor-Camshaft 1/1 Position > Page 1036 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Sensor-Camshaft 1/1 Position > Page 1037 Camshaft Position Sensor: Locations Sensor-Camshaft 1/2 Position Component ID: 285 Component : SENSOR-CAMSHAFT 1/2 POSITION Connector: Name : SENSOR-CAMSHAFT 1/2 POSITION Color : BLACK # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K915 20BR/WT 3 CMP 1/2 SIGNAL K441 20DB/BR Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Sensor-Camshaft 1/1 Position > Page 1038 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Sensor-Camshaft 1/1 Position Camshaft Position Sensor: Diagrams Sensor-Camshaft 1/1 Position Component ID: 284 Component : SENSOR-CAMSHAFT 1/1 POSITION Connector: Name : SENSOR-CAMSHAFT 1/1 POSITION Color : BLACK # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY K857 20BR/LG 2 SENSOR GROUND K900 20DB/DG 3 CMP 1/1 SIGNAL K44 20DB Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Sensor-Camshaft 1/1 Position > Page 1041 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Sensor-Camshaft 1/1 Position > Page 1042 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Sensor-Camshaft 1/1 Position > Page 1043 Camshaft Position Sensor: Diagrams Sensor-Camshaft 1/2 Position Component ID: 285 Component : SENSOR-CAMSHAFT 1/2 POSITION Connector: Name : SENSOR-CAMSHAFT 1/2 POSITION Color : BLACK # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K915 20BR/WT 3 CMP 1/2 SIGNAL K441 20DB/BR Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Sensor-Camshaft 1/1 Position > Page 1044 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Description Camshaft Position Sensor: Description and Operation Description DESCRIPTION The camshaft position sensors are mounted to the front and rear of the cylinder head. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Description > Page 1047 Camshaft Position Sensor: Description and Operation Operation OPERATION The PCM sends approximately 5 volts to the Hall-effect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. The input to the PCM occurs on a 5 volt output reference circuit. A ground for the sensor is provided through the sensor return circuit. The PCM identifies camshaft position by registering the change from 5 to 0 volts, as signaled from the camshaft position sensor. The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Removal Camshaft Position Sensor: Service and Repair Removal Front Camshaft Position Sensor FRONT CAMSHAFT POSITION SENSOR 1. Remove the air cleaner hose to throttle body, disconnect the inlet air temperature sensor electrical connector. 2. Disconnect negative battery cable. 3. Disconnect electrical connector from camshaft position sensor. 4. Remove camshaft position sensor mounting screws. 5. Remove sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 1050 Rear Camshaft Position Sensor REAR CAMSHAFT POSITION SENSOR 1. Disconnect negative battery cable. 2. Disconnect electrical connector at sensor. 3. Remove nut retaining heat shield. 4. Pull heat shield out to uncover sensor. 5. Remove mounting bolt. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 1051 6. Remove sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 1052 Camshaft Position Sensor: Service and Repair Installation Front Camshaft Position Sensor FRONT CAMSHAFT POSITION SENSOR 1. Lubricate sensor O-ring. 2. Install camshaft position sensor utilizing twisting motion. Make sure sensor is fully seated. Do not drive sensor into the bore with screw. This can cause sensor to be incorrectly seated causing engine to fail. Tighten sensor mounting screws to 9 Nm (79.5 in. lbs.). 3. Carefully attach electrical connector to camshaft position sensor. Installation at an angle may damage the sensor pins. 4. Install the negative battery cable. 5. Install the air cleaner to throttle body hose, connect the inlet air temperature sensor electrical connector. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 1053 Rear Camshaft Position Sensor REAR CAMSHAFT POSITION SENSOR 1. Lubricate sensor O-ring. 2. Install sensor utilizing twisting motion. Make sure sensor is fully seated. Do not drive sensor into the bore with screw. This can cause sensor to be incorrectly seated causing engine to fail. 3. Install mounting bolt and tighten to 9 Nm (79.5 in. lbs.). 4. Carefully attach electrical connector to camshaft position sensor. Fill for positive lock (click). Installation at angle may damage the sensor pins. 5. Install heat shield onto mounting stud. 6. Install heat shield retaining nut and tighten. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 1054 7. Connect the electrical connector. 8. Connect negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Component ID: 287 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 CKP SENSOR 5 VOLT SUPPLY K853 20DB/BR 2 CKP SENSOR SIGNAL K24 20BR/LB 3 CKP SENSOR GROUND K925 20DB/WT Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1058 Component Location - 19 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1059 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1060 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20LB/BR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1061 Component Location - 16 Component Location - 19 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1062 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1063 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1064 Crankshaft Position Sensor: Diagrams Component ID: 287 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 CKP SENSOR 5 VOLT SUPPLY K853 20DB/BR 2 CKP SENSOR SIGNAL K24 20BR/LB 3 CKP SENSOR GROUND K925 20DB/WT Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1065 Component Location - 19 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1066 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1067 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20LB/BR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1068 Component Location - 16 Component Location - 19 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1069 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1070 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description DESCRIPTION The crankshaft position sensor mounts to the rear of the engine block near the transmission. The PCM uses the Crankshaft Position sensor to calculate the following: - Engine RPM - TDC number 1 and 4 - Ignition coil synchronization - Injector synchronization - Camshaft-to-crankshaft misalignment (Timing belt skipped 1 tooth or more diagnostic trouble code). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 1073 Crankshaft Position Sensor: Description and Operation Operation OPERATION The PCM sends approximately 5 volts to the Hall-effect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. A ground for the sensor is provided through the sensor return circuit. The input to the PCM occurs on a 5 volt output reference circuit that operates as follows: The Hall-effect sensor contains a powerful magnet. As the magnetic field passes over the dense portion of the counterweight, the 5-volt signal is pulled to ground (0.3 volts) through a transistor in the sensor. When the magnetic field passes over the notches in the crankshaft counterweight, the magnetic field turns off the transistor in the sensor, causing the PCM to register the 5-volt signal. The PCM identifies crankshaft position by registering the change from 5 to 0 volts, as signaled from the Crankshaft Position sensor (2). The PCM determines which cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. The #8 crankshaft counterweight has a target ring with 32 teeth and notches (1), including one long reference tooth and notch. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Removal Crankshaft Position Sensor: Service and Repair Removal 2.0/2.4L The Crankshaft Position Sensor is in the rear of the engine block near the transmission. If vehicle is All Wheel Drive the Power Transfer Unit must be removed. 1. Disconnect the negative battery cable. 2. Raise vehicle and support. 3. Remove heat shield retaining bolt. 4. Remove heat shield. 5. Unlock and disconnect the electrical connector to the crankshaft position sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Removal > Page 1076 6. Remove the crankshaft position sensor bolt. 7. Remove the sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Removal > Page 1077 Crankshaft Position Sensor: Service and Repair Installation 2.0/2.4L 1. Check O-ring for damage and lubricate the O-ring with engine oil before installing sensor. 2. Use a twisting motion when installing the sensor. 3. Install and tighten the crankshaft position sensor bolt and tighten to 9 Nm (79.5 in. lbs.). 4. Connect and lock the electrical connector to the crankshaft position sensor. 5. Install heat shield and retaining bolt. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Removal > Page 1078 If vehicle is All Wheel Drive the Power Transfer Unit must be installed. 6. Lower vehicle. 7. Connect the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder Ignition Switch Lock Cylinder: Service and Repair Key/Lock Cylinder Removal REMOVAL 1. Access and remove the Steering Column Control Module (SCCM) (3) from the steering column (2). 2. If equipped with Thatcham security (Export), remove the screws securing the cup (1) over the key cylinder. Remove the cup. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 1084 3. Remove the screw (1) fastening the SKREEM/WCM (2) to the lock cylinder housing (3). 4. Unhook the SKREEM/WCM (2) retainer fingers from the lock cylinder housing (3) and remove it. 5. Insert the key (2) and turn the key cylinder (3) to the RUN position. 6. Insert an appropriate tool into the slot (1) formed into the lock cylinder housing depressing the key cylinder retaining tab. 7. Pull the key cylinder and key straight out of the lock cylinder housing as one unit. 8. Using a Tamper-Proof Torx(R) Plus (five point) 30 bit, remove the two screws (1) fastening the lock cylinder housing (2) to the column. 9. Remove the lock cylinder housing from the steering column. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 1085 10. Remove the ignition module (2) mounting screw (1). 11. Pull the module (1) straight out and off the retaining tabs (2) located on the lock cylinder housing. Installation INSTALLATION NOTE: Ignition module must be installed prior to lock housing installation on column. Otherwise, the tilt lever will obstruct installation of ignition switch. 1. Ensure the ignition module is in the RUN position and the actuator shaft in the lock housing is in the RUN position. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 1086 2. Align the ignition module with the pin (3), actuator shaft and retaining tabs (2) located on the lock cylinder housing. Carefully install the module, snapping it into place over the retaining tabs. 3. Install the ignition module (2) mounting screw (1). Tighten the screw to 2 Nm (18 in. lbs.). NOTE: Ignition module needs to be installed on lock cylinder housing before housing installation to clear tilt lever. 4. Position the lock cylinder housing in the RUN position. 5. Align the lock cylinder housing (2) with the steering column. 6. Install the two screws (1) fastening the lock cylinder housing (2) to the column. Tighten the screws to 12 Nm (110 in. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 1087 7. Place the actuator in the lock cylinder housing to the RUN position (if not already there). 8. Insert the key into the key cylinder and turn the key cylinder to the RUN position. 9. Align the retaining tab on the key cylinder with the slot in the top of the lock cylinder housing. 10. Slide the key cylinder into the lock cylinder housing until the key cylinder retaining tab locks the cylinder into place. 11. Rotate the key back and forth (OFF to START), then remove and reinstall it, making sure the key cylinder and lock cylinder housing operate properly. 12. Slide the ring of the SKREEM/WCM (2) over the lock cylinder housing (3) and engage the retainer fingers in the recesses formed on the lock cylinder housing. 13. Install the screw (1) fastening the SKREEM/WCM (2) to the lock cylinder housing (3). Tighten the screw to 2.5 Nm (22 in. lbs.). 14. If equipped with Thatcham security (Export), install the cup (1) over the key cylinder and install the two mounting screws. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 1088 15. Install the Steering Column Control Module (SCCM) (3) and all components removed to access it. 16. Check operation of all steering column mounted components. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 1089 Ignition Switch Lock Cylinder: Service and Repair Housing-Lock Cylinder Removal REMOVAL 1. Access and remove the Steering Column Control Module (SCCM) (3) from the steering column (2). 2. If equipped with Thatcham security, remove the screws securing the cup (1) over the key cylinder. Remove the cup. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 1090 3. Remove the screw (1) fastening the SKREEM/WCM (2) to the lock cylinder housing (3). 4. Unhook the SKREEM/WCM (2) retainer fingers from the lock cylinder housing (3) and remove it. 5. Insert the key (2) and turn the key cylinder (3) to the RUN position. 6. Insert an appropriate tool into the slot (1) formed into the lock cylinder housing depressing the key cylinder retaining tab. 7. Pull the key cylinder and key straight out of the lock cylinder housing as one unit. 8. Using a Tamper-Proof Torx(R) Plus (five point) 30 bit, remove the two screws (1) fastening the lock cylinder housing (2) to the column. 9. Remove the lock cylinder housing from the steering column. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 1091 10. Remove the ignition module (2) mounting screw (1). 11. Pull the module (1) straight out and off the retaining tabs (2) located on the lock cylinder housing. Installation INSTALLATION NOTE: Ignition module must be installed prior to lock housing installation on column. Otherwise, the tilt lever will obstruct installation of ignition switch. 1. Ensure the ignition module is in the RUN position and the actuator shaft in the lock housing is in the RUN position. 2. Align the ignition module with the pin (3), actuator shaft and retaining tabs (2) located on the lock cylinder housing. Carefully install the module, snapping it into place over the retaining tabs. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 1092 3. Install the ignition module (2) mounting screw (1). Tighten the screw to 2 Nm (18 in. lbs.). NOTE: Ignition module needs to be installed on lock cylinder housing before housing installation to clear tilt lever. 4. Position the lock cylinder housing in the RUN position. 5. Align the lock cylinder housing (2) with the steering column. 6. Install the two screws (1) fastening the lock cylinder housing (2) to the column. Tighten the screws to 12 Nm (110 in. lbs.). 7. Place the actuator in the lock cylinder housing to the RUN position (if not already there). 8. Insert the key into the key cylinder and turn the key cylinder to the RUN position. 9. Align the retaining tab on the key cylinder with the slot in the top of the lock cylinder housing. 10. Slide the key cylinder into the lock cylinder housing until the key cylinder retaining tab locks the cylinder into place. 11. Rotate the key back and forth (OFF to START), then remove and reinstall it, making sure the key cylinder and lock cylinder housing operate Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 1093 properly. 12. Slide the ring of the SKREEM/WCM (2) over the lock cylinder housing (3) and engage the retainer fingers in the recesses formed on the lock cylinder housing. 13. Install the screw (1) fastening the SKREEM/WCM (2) to the lock cylinder housing (3). Tighten the screw to 2.5 Nm (22 in. lbs.). 14. If equipped with Thatcham security, install the cup (1) over the key cylinder and install the two mounting screws. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 1094 15. Install the Steering Column Control Module (SCCM) (3) and all components removed to access it. 16. Check operation of all steering column mounted components. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Component ID: 299 Component : SENSOR-KNOCK Connector: Name : SENSOR-KNOCK Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 KS SIGNAL K42 20LG/DB 2 KS RETURN K942 20WT/BR Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 1098 Component Location - 15 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 1099 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 1100 Knock Sensor: Diagrams Component ID: 299 Component : SENSOR-KNOCK Connector: Name : SENSOR-KNOCK Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 KS SIGNAL K42 20LG/DB 2 KS RETURN K942 20WT/BR Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 1101 Component Location - 15 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 1102 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Description Knock Sensor: Description and Operation Description DESCRIPTION The knock sensor is bolted to the cylinder block. The knock sensor is designed to detect engine vibration that is caused by detonation or preignition. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Description > Page 1105 Knock Sensor: Description and Operation Operation OPERATION When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives as an input the knock sensor voltage signal. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, ignition timing retard is allowed. Ignition timing is retarded uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard ignition timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except WOT. The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening affects knock sensor performance, possibly causing improper spark control. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Removal Knock Sensor: Service and Repair Removal 2.0/2.4L The knock sensor bolts into the side of the cylinder block in front of the starter under the intake manifold. 1. Disconnect the negative battery cable. 2. Remove the bolt holding the knock sensor. 3. Remove sensor with electrical connector attached. 4. Disconnect electrical connector from knock sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Removal > Page 1108 5. Remove the knock sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Removal > Page 1109 Knock Sensor: Service and Repair Installation 2.0/2.4L The knock sensor bolts into the side of the cylinder block in front of the starter under the intake manifold. 1. Attach electrical connector to knock sensor. 2. Install knock sensor. Tighten knock sensor bolt to 22 Nm (195 in. lbs.). Over or under tightening effects knock sensor performance, possibly causing improper spark control. 3. Connect the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left Impact Sensor: Locations Sensor-Front Impact-Left Component ID: 293 Component : SENSOR-FRONT IMPACT-LEFT Connector: Name : SENSOR-FRONT IMPACT-LEFT Color : YELLOW # of pins : 2 Pin Description Circuit 1 LEFT FRONT IMPACT SENSOR GROUND R81 20LB/WT 2 LEFT FRONT IMPACT SENSOR SIGNAL R79 20LB/VT Component Location - 7 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 1115 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 1116 Impact Sensor: Locations Sensor-Side Impact-Left 1 Component ID: 312 Component : SENSOR-SIDE IMPACT-LEFT 1 Connector: Name : SENSOR-SIDE IMPACT-LEFT 1 Color : YELLOW # of pins : 4 Pin Description Circuit 1 LEFT SIDE IMPACT SENSOR 1 SIGNAL R13 20LG/TN 2 LEFT SIDE IMPACT SENSOR 1 GROUND R15 20LG/BR 3 LEFT SIDE IMPACT SENSOR 2 GROUND R19 20LG/WT 4 LEFT SIDE IMPACT SENSOR 2 SIGNAL R17 20LG/LB Component Location - 48 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 1117 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 1118 Impact Sensor: Locations Sensor-Side Impact-Left 2 Component ID: 313 Component : SENSOR-SIDE IMPACT-LEFT 2 Connector: Name : SENSOR-SIDE IMPACT-LEFT 2 Color : YELLOW # of pins : 2 Pin Description Circuit 1 LEFT SIDE IMPACT SENSOR 2 GROUND R19 20LG/WT 2 LEFT SIDE IMPACT SENSOR 2 SIGNAL R17 20LG/LB Component Location - 60 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 1119 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 1120 Impact Sensor: Locations Sensor-Side Impact-Right 1 Component ID: 314 Component : SENSOR-SIDE IMPACT-RIGHT 1 Connector: Name : SENSOR-SIDE IMPACT-RIGHT 1 Color : YELLOW # of pins : 4 Pin Description Circuit 1 RIGHT SIDE IMPACT SENSOR 1 SIGNAL R14 20TN/LG 2 RIGHT SIDE IMPACT SENSOR 1 GROUND R16 20BR/LG 3 RIGHT SIDE IMPACT SENSOR 2 GROUND R20 20WT/LG 4 RIGHT SIDE IMPACT SENSOR 2 SIGNAL R18 20LB/LG Component Location - 50 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 1121 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 1122 Impact Sensor: Locations Sensor-Side Impact-Right 2 Component ID: 315 Component : SENSOR-SIDE IMPACT-RIGHT 2 Connector: Name : SENSOR-SIDE IMPACT-RIGHT 2 Color : YELLOW # of pins : 2 Pin Description Circuit 1 RIGHT SIDE IMPACT SENSOR 2 GROUND R20 20WT/LG 2 RIGHT SIDE IMPACT SENSOR 2 SIGNAL R18 20LB/LG Component Location - 63 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 1123 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left Impact Sensor: Diagrams Sensor-Front Impact-Left Component ID: 293 Component : SENSOR-FRONT IMPACT-LEFT Connector: Name : SENSOR-FRONT IMPACT-LEFT Color : YELLOW # of pins : 2 Pin Description Circuit 1 LEFT FRONT IMPACT SENSOR GROUND R81 20LB/WT 2 LEFT FRONT IMPACT SENSOR SIGNAL R79 20LB/VT Component Location - 7 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 1126 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 1127 Impact Sensor: Diagrams Sensor-Side Impact-Left 1 Component ID: 312 Component : SENSOR-SIDE IMPACT-LEFT 1 Connector: Name : SENSOR-SIDE IMPACT-LEFT 1 Color : YELLOW # of pins : 4 Pin Description Circuit 1 LEFT SIDE IMPACT SENSOR 1 SIGNAL R13 20LG/TN 2 LEFT SIDE IMPACT SENSOR 1 GROUND R15 20LG/BR 3 LEFT SIDE IMPACT SENSOR 2 GROUND R19 20LG/WT 4 LEFT SIDE IMPACT SENSOR 2 SIGNAL R17 20LG/LB Component Location - 48 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 1128 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 1129 Impact Sensor: Diagrams Sensor-Side Impact-Left 2 Component ID: 313 Component : SENSOR-SIDE IMPACT-LEFT 2 Connector: Name : SENSOR-SIDE IMPACT-LEFT 2 Color : YELLOW # of pins : 2 Pin Description Circuit 1 LEFT SIDE IMPACT SENSOR 2 GROUND R19 20LG/WT 2 LEFT SIDE IMPACT SENSOR 2 SIGNAL R17 20LG/LB Component Location - 60 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 1130 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 1131 Impact Sensor: Diagrams Sensor-Side Impact-Right 1 Component ID: 314 Component : SENSOR-SIDE IMPACT-RIGHT 1 Connector: Name : SENSOR-SIDE IMPACT-RIGHT 1 Color : YELLOW # of pins : 4 Pin Description Circuit 1 RIGHT SIDE IMPACT SENSOR 1 SIGNAL R14 20TN/LG 2 RIGHT SIDE IMPACT SENSOR 1 GROUND R16 20BR/LG 3 RIGHT SIDE IMPACT SENSOR 2 GROUND R20 20WT/LG 4 RIGHT SIDE IMPACT SENSOR 2 SIGNAL R18 20LB/LG Component Location - 50 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 1132 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 1133 Impact Sensor: Diagrams Sensor-Side Impact-Right 2 Component ID: 315 Component : SENSOR-SIDE IMPACT-RIGHT 2 Connector: Name : SENSOR-SIDE IMPACT-RIGHT 2 Color : YELLOW # of pins : 2 Pin Description Circuit 1 RIGHT SIDE IMPACT SENSOR 2 GROUND R20 20WT/LG 2 RIGHT SIDE IMPACT SENSOR 2 SIGNAL R18 20LB/LG Component Location - 63 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 1134 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Front Impact Sensor: Description and Operation Front Description FRONT Two front impact sensors (1) are used on this vehicle, one each for the left and right sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). Each front sensor is secured with a screw to the backs of the right and left vertical members of the radiator support within the engine compartment. The right and left front impact sensors are identical in construction and calibration. A cavity in the center of the molded black plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material that fills the cavity to seal and protect the internal electronic circuitry and components. The front impact sensors are each connected to the vehicle electrical system through the headlamp and dash wire harness. The impact sensors cannot be repaired or adjusted and, if damaged or ineffective, they must be replaced. Operation FRONT The front impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the passive restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through dedicated left and right sensor plus and minus circuits from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor plus circuit. To diagnose the impact sensors or the electronic controls and communication related to front impact sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Front > Page 1137 Impact Sensor: Description and Operation Side Description SIDE Four side impact sensors (1) are used on this vehicle when it is equipped with the optional side airbags, two each for the left and right sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). Each side sensor is secured with a screw to the right or left B-pillar and C-pillar. The right and left side impact sensors are identical in construction and calibration. A cavity in the center of the molded black plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material fills the cavity to seal and protect the internal electronic circuitry and components. The side impact sensors are each connected to the vehicle electrical system through the body wire harness. The impact sensors cannot be repaired or adjusted and, if damaged or ineffective, they must be replaced. Operation SIDE The side impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the side passive restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through the same left or right sensor plus and minus circuits in a series arrangement from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor plus circuit. To diagnose the impact sensors or the electronic controls and communication related to side impact sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal Impact Sensor: Service and Repair Removal Front FRONT 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the system reserve capacitor to discharge before servicing any airbag components. 2. Remove the screw (4) that secures the right or left front impact sensor (3) to the back of the right or left radiator support vertical member (2). 3. Disconnect the connector (1) from the sensor (3). 4. Remove the right or left front impact sensor from the engine compartment. Side - B-Pillar SIDE - B-PILLAR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal > Page 1140 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the system reserve capacitor to discharge before servicing any airbag components. 2. Remove the B-pillar lower trim panel. 3. Disconnect the harness connector (4) from the sensor (2). 4. Remove the screw (1) retaining the B-pillar side impact sensor (2) 5. Remove the sensor (2) from the vehicle. Side - C-Pillar SIDE - C-PILLAR 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the system reserve capacitor to discharge before servicing any airbag components. 2. Remove the rear quarter panel trim. 3. Remove the screw (4) that secures the side impact sensor (3) to the C-pillar (1). 4. Disconnect the harness connector (2) from the sensor (3). 5. Remove the sensor from the C-pillar. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal > Page 1141 Impact Sensor: Service and Repair Installation Front FRONT 1. Position the right or left front impact sensor (3) into the engine compartment near it mounting area. 2. Connect the harness connector (1) to the sensor. 3. Position the sensor onto the back of the right or left radiator support vertical member (2). NOTE: Be certain that the anti-rotation pin on the back of the sensor is engaged in the lower clearance hole of the radiator support. 4. Install and tighten the screw (4) that secures the sensor (3) to the back of the support vertical member (2). Tighten the screw to 8 Nm (71 in. lbs.). WARNING: Do not connect the battery negative cable. Personal injury or death may result if the system test is not performed first. Side - B-Pillar SIDE - B-PILLAR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal > Page 1142 1. Position the sensor onto the B-pillar and install the mounting screw (1). Tighten the screw to 8 Nm (71 in. lbs.). NOTE: Be certain that the anti-rotation pin on the back of the sensor is engaged in the hole just below the mounting hole in the B-pillar (3). 2. Connect the harness connector (4) to the sensor (2). 3. Install the B-pillar lower trim panel. WARNING: Do not connect the battery negative cable. Personal injury or death may result if the system test is not performed first. Side - C-Pillar SIDE - C-PILLAR 1. Position the side impact sensor near the inner C-pillar. 2. Connect the harness connector (2) to the sensor (3). 3. Position the sensor onto the C-pillar. NOTE: Be certain that the anti-rotation pin on the back of the sensor is engaged in the clearance hole on the C-pillar below the sensor mounting hole. 4. Install screw (4) that secures the sensor (3) to the C-pillar (1). Tighten the screw to 8 Nm (71 in. lbs.). 5. Install the rear quarter panel trim. WARNING: Do not connect the battery negative cable. Personal injury or death may result if the system test is not performed first. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Description and Operation > Description Seat Occupant Sensor: Description and Operation Description DESCRIPTION The seat weight sensors are strain gauge-type units. The electronic elements of the sensor are encased within the sensor body (4). Four sensors are used in the Occupant Classification System (OCS). The sensors are located below the seat cushion between the seat adjuster track and the seat adjuster riser at each corner of the passenger side front seat. A threaded mounting stud (2) on each sensor body is secured by a nut to the seat adjuster riser, and two nuts secure each sensor mounting flange (1) to two studs integral to the front and rear of the inboard and outboard passenger side lower seat adjuster tracks. A molded connector receptacle (3) integral to each sensor body is oriented towards the center of the seat and is connected to the vehicle electrical system through a dedicated connector and take out of the passenger seat wire harness beneath the seat cushion. The seat weight sensors cannot be adjusted or repaired and, if faulty or damaged, the entire sensor must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Description and Operation > Description > Page 1147 Seat Occupant Sensor: Description and Operation Operation OPERATION The seat weight sensor units are designed to sense the relative weight of a load applied to the passenger side front seat, which provides a logic input to the microprocessor of the Occupant Classification Module (OCM). When any load is applied to the seat the load is transmitted through the sensor mounting flange to the sensor body (strain gauge) of each sensor, causing a change of electrical resistance through the strain gauge. These changes in resistance within the internal sensor circuitry change the sensor output voltage. Each weight sensor receives a nominal five volts and a clean ground through parallel hard wired circuits from the OCM. The OCM then monitors the output voltage of each sensor on dedicated hard wired data communication circuits. The hard wired circuits between the sensors and the OCM may be diagnosed and tested using conventional diagnostic tools and procedures. However, the most reliable, efficient, and accurate means to diagnose the seat weight sensor inputs to the OCM, and the electronic message communication between the OCM and the Occupant Restraint Controller (ORC) requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Service and Repair > Removal Seat Occupant Sensor: Service and Repair Removal REMOVAL WARNING: To avoid personal injury or death, never strike or drop a seat weight sensor or the passenger side front seat assembly to which the sensors are secured as it can damage the sensors or affect their calibration. The seat weight sensors and the passenger side front seat assembly must be handled with care to avoid damage to the sensors. Do not sit upon or place any loads upon a passenger side front seat while it is removed from its mounts in or outside of the vehicle. If an individual sensor is dropped or damaged, replace the sensor with a new and unused unit. If a seat has been dropped during removal or loaded while removed from its mounts, replace each of the seat weight sensors with new and unused units. Failure to observe this warning could result in an accidental, incomplete, or improper passenger side front supplemental restraint deployment. 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the system reserve capacitor to discharge before servicing any airbag components. 2. Remove the passenger front seat from the vehicle as a unit. CAUTION: Strain gauge alignment tool 9689 (2) must be used to secure the body of the seat weight sensor (1) from any rotation during removal or installation of the nut that secures the sensor stud to the seat adjuster riser. In addition, the sensor fasteners should always be serviced using hand tools ONLY, and not electric or pneumatic power tools. Failure to observe these precautions may result in irreversible sensor damage and require sensor replacement. 3. Remove the passenger front seat riser from the seat. 4. Disconnect each weight sensor electrical connector and install strain gauge alignment tool 9689. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Service and Repair > Removal > Page 1150 5. Insert the fork (1) into weight sensor and seat the support yoke (2) firmly against the weight sensor cage. 6. Remove center stud nut and repeat these steps for each of the four weight sensors. 7. Separate the seat track from the seat risers. 8. Remove the nuts securing the seat weight sensor to the adjuster track and remove the seat weight sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Service and Repair > Removal > Page 1151 Seat Occupant Sensor: Service and Repair Installation INSTALLATION WARNING: To avoid personal injury or death, never strike or drop a seat weight sensor or the passenger side front seat assembly to which the sensors are secured as it can damage the sensors or affect their calibration. The seat weight sensors and the passenger side front seat assembly must be handled with care to avoid damage to the sensors. Do not sit upon or place any loads upon a passenger side front seat while it is removed from its mounts in or outside of the vehicle. If an individual sensor is dropped or damaged, replace the sensor with a new and unused unit. If a seat has been dropped during removal or loaded while removed from its mounts, replace each of the seat weight sensors with new and unused units. Failure to observe this warning could result in an accidental, incomplete, or improper passenger side front supplemental restraint deployment. WARNING: To avoid personal injury or death on vehicles equipped with the Occupant Classification System (OCS), any time the passenger side front seat assembly has been removed or loosened from the vehicle for service of any vehicle component or system the Occupant Classification System Verification Test must be performed using a diagnostic scan tool and the Occupant Classification Seat Weight special tool following reinstallation. Refer to the appropriate diagnostic procedures. Failure to observe this warning could result in an accidental, incomplete, or improper passenger side front supplemental restraint deployment. CAUTION: Strain gauge alignment tool 9689 (2) must be used to secure the body of the seat weight sensor (1) from any rotation during removal or installation of the nut that secures the sensor stud to the seat adjuster riser. In addition, the sensor fasteners should always be serviced using hand tools ONLY, and not electric or pneumatic power tools. Failure to observe these precautions may result in irreversible sensor damage and require sensor replacement. 1. Install the seat weight sensor and install the nuts securing the seat weight sensor to the adjuster track. Tighten nuts to 28 Nm (21 ft. lbs.). 2. Place the seat track onto the seat riser. 3. Install the nut on the center stud and repeat for each of the four weight sensors. CAUTION: Do not tighten the center nut to the seat weight sensors without the use of strain gauge alignment tool 9689. 4. Insert the fork (1) into weight sensor and seat the support yoke (2) firmly against the weight sensor cage. Tighten nut to 45 Nm (33 ft. lbs.). Repeat for all four sensors. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Service and Repair > Removal > Page 1152 5. Connect each weight sensor electrical connector. 6. Reinstall the passenger front seat. WARNING: Do not connect the battery negative cable. Personal injury or death may result if the system test is not performed first. WARNING: Following successful completion of the Airbag System verification test procedure, perform the Occupant Classification System Verification Test using a diagnostic scan tool and the Occupant Classification Seat Weight special tool 9077. Refer to the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver Seat Sensor/Switch: Locations Sensor-Seat Track Position-Driver Component ID: 306 Component : SENSOR-SEAT TRACK POSITION-DRIVER Connector: Name : SENSOR-SEAT TRACK POSITION-DRIVER Color : DK. GRAY # of pins : 2 Pin Description Circuit 1 DRIVER SEAT POSITION SENSOR DATA R261 20LB/WT 2 DRIVER SEAT POSITION SENSOR VOLTAGER263 20LB/VT Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 1157 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 1158 Seat Sensor/Switch: Locations Sensor-Seat Track Position-Passenger Component ID: 307 Component : SENSOR-SEAT TRACK POSITION-PASSENGER Connector: Name : SENSOR-SEAT TRACK POSITION-PASSENGER Color : DK. GRAY # of pins : 2 Pin Description Circuit 1 PASSENGER SEAT POSITION SENSOR DATAR262 20WT/LB 2 PASSENGER SEAT POSITION SENSOR VOLTAGE R264 20VT/LB Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 1159 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 1160 Seat Sensor/Switch: Locations Sensor-Seat Weight-Left Front Component ID: 308 Component : SENSOR-SEAT WEIGHT-LEFT FRONT Connector: Name : SENSOR-SEAT WEIGHT-LEFT FRONT Color : BLACK # of pins : 3 Pin Description Circuit 1 SEAT WEIGHT SENSOR GROUND R728 20LB/YL 2 SEAT WEIGHT LEFT FRONT SENSOR SIGNAL R717 20LG/DG 3 SEAT WEIGHT SENSOR 5 VOLT R701 20LG Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 1161 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 1162 Seat Sensor/Switch: Locations Sensor-Seat Weight-Left Rear Component ID: 309 Component : SENSOR-SEAT WEIGHT-LEFT REAR Connector: Name : SENSOR-SEAT WEIGHT-LEFT REAR Color : BLACK # of pins : 3 Pin Description Circuit 1 SEAT WEIGHT SENSOR GROUND R728 20LB/YL 2 SEAT WEIGHT LEFT REAR SENSOR SIGNALR705 20LG/OR 3 SEAT WEIGHT SENSOR 5 VOLT R701 20LG Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 1163 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 1164 Seat Sensor/Switch: Locations Sensor-Seat Track Position-Driver Component ID: 306 Component : SENSOR-SEAT TRACK POSITION-DRIVER Connector: Name : SENSOR-SEAT TRACK POSITION-DRIVER Color : DK. GRAY # of pins : 2 Pin Description Circuit 1 DRIVER SEAT POSITION SENSOR DATA R261 20LB/WT 2 DRIVER SEAT POSITION SENSOR VOLTAGER263 20LB/VT Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 1165 Sensor-Seat Track Position-Passenger Component ID: 307 Component : SENSOR-SEAT TRACK POSITION-PASSENGER Connector: Name : SENSOR-SEAT TRACK POSITION-PASSENGER Color : DK. GRAY # of pins : 2 Pin Description Circuit Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 1166 1 PASSENGER SEAT POSITION SENSOR DATAR262 20WT/LB 2 PASSENGER SEAT POSITION SENSOR VOLTAGE R264 20VT/LB Component Location - 57 Sensor-Seat Weight-Left Front Component ID: 308 Component : SENSOR-SEAT WEIGHT-LEFT FRONT Connector: Name : SENSOR-SEAT WEIGHT-LEFT FRONT Color : BLACK # of pins : 3 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 1167 Pin Description Circuit 1 SEAT WEIGHT SENSOR GROUND R728 20LB/YL 2 SEAT WEIGHT LEFT FRONT SENSOR SIGNAL R717 20LG/DG 3 SEAT WEIGHT SENSOR 5 VOLT R701 20LG Component Location - 57 Sensor-Seat Weight-Left Rear Component ID: 309 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 1168 Component : SENSOR-SEAT WEIGHT-LEFT REAR Connector: Name : SENSOR-SEAT WEIGHT-LEFT REAR Color : BLACK # of pins : 3 Pin Description Circuit 1 SEAT WEIGHT SENSOR GROUND R728 20LB/YL 2 SEAT WEIGHT LEFT REAR SENSOR SIGNALR705 20LG/OR 3 SEAT WEIGHT SENSOR 5 VOLT R701 20LG Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 1169 Sensor-Seat Weight-Right Front Component ID: 310 Component : SENSOR-SEAT WEIGHT-RIGHT FRONT Connector: Name : SENSOR-SEAT WEIGHT-RIGHT FRONT Color : BLACK # of pins : 3 Pin Description Circuit Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 1170 1 SEAT WEIGHT SENSOR GROUND R728 20LB/YL 2 SEAT WEIGHT RIGHT FRONT SENSOR SIGNAL R718 20LB/DG 3 SEAT WEIGHT SENSOR 5 VOLT R701 20LG Component Location - 57 Sensor-Seat Weight-Right Rear Component ID: 311 Component : SENSOR-SEAT WEIGHT-RIGHT REAR Connector: Name : SENSOR-SEAT WEIGHT-RIGHT REAR Color : BLACK # of pins : 3 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 1171 Pin Description Circuit 1 SEAT WEIGHT SENSOR GROUND R728 20LB/YL 2 SEAT WEIGHT RIGHT REAR SENSOR SIGNAL R706 20LB/OR 3 SEAT WEIGHT SENSOR 5 VOLT R701 20LG Component Location - 57 Switch-Seat Belt-Driver Component ID: 355 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 1172 Component : SWITCH-SEAT BELT-DRIVER Connector: Name : SWITCH-SEAT BELT-DRIVER Color : BLACK # of pins : 2 Pin Description Circuit 1 DRIVER SEAT BELT SWITCH SENSE R57 20LG/GY 2 GROUND Z961 20BK/YL Component Location - 48 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 1173 Switch-Seat Belt-Passenger Component ID: 356 Component : SWITCH-SEAT BELT-PASSENGER Connector: Name : SWITCH-SEAT BELT-PASSENGER Color : WHITE # of pins : 2 Pin Description Circuit Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 1174 1 PASSENGER HALL EFFECT (+) R274 20LB/WT 2 PASSENGER HALL EFFECT (-) R272 20LB/VT Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver Seat Sensor/Switch: Diagrams Sensor-Seat Track Position-Driver Component ID: 306 Component : SENSOR-SEAT TRACK POSITION-DRIVER Connector: Name : SENSOR-SEAT TRACK POSITION-DRIVER Color : DK. GRAY # of pins : 2 Pin Description Circuit 1 DRIVER SEAT POSITION SENSOR DATA R261 20LB/WT 2 DRIVER SEAT POSITION SENSOR VOLTAGER263 20LB/VT Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 1177 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 1178 Seat Sensor/Switch: Diagrams Sensor-Seat Track Position-Passenger Component ID: 307 Component : SENSOR-SEAT TRACK POSITION-PASSENGER Connector: Name : SENSOR-SEAT TRACK POSITION-PASSENGER Color : DK. GRAY # of pins : 2 Pin Description Circuit 1 PASSENGER SEAT POSITION SENSOR DATAR262 20WT/LB 2 PASSENGER SEAT POSITION SENSOR VOLTAGE R264 20VT/LB Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 1179 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 1180 Seat Sensor/Switch: Diagrams Sensor-Seat Weight-Left Front Component ID: 308 Component : SENSOR-SEAT WEIGHT-LEFT FRONT Connector: Name : SENSOR-SEAT WEIGHT-LEFT FRONT Color : BLACK # of pins : 3 Pin Description Circuit 1 SEAT WEIGHT SENSOR GROUND R728 20LB/YL 2 SEAT WEIGHT LEFT FRONT SENSOR SIGNAL R717 20LG/DG 3 SEAT WEIGHT SENSOR 5 VOLT R701 20LG Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 1181 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 1182 Seat Sensor/Switch: Diagrams Sensor-Seat Weight-Left Rear Component ID: 309 Component : SENSOR-SEAT WEIGHT-LEFT REAR Connector: Name : SENSOR-SEAT WEIGHT-LEFT REAR Color : BLACK # of pins : 3 Pin Description Circuit 1 SEAT WEIGHT SENSOR GROUND R728 20LB/YL 2 SEAT WEIGHT LEFT REAR SENSOR SIGNALR705 20LG/OR 3 SEAT WEIGHT SENSOR 5 VOLT R701 20LG Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 1183 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 1184 Seat Sensor/Switch: Diagrams Sensor-Seat Track Position-Driver Component ID: 306 Component : SENSOR-SEAT TRACK POSITION-DRIVER Connector: Name : SENSOR-SEAT TRACK POSITION-DRIVER Color : DK. GRAY # of pins : 2 Pin Description Circuit 1 DRIVER SEAT POSITION SENSOR DATA R261 20LB/WT 2 DRIVER SEAT POSITION SENSOR VOLTAGER263 20LB/VT Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 1185 Sensor-Seat Track Position-Passenger Component ID: 307 Component : SENSOR-SEAT TRACK POSITION-PASSENGER Connector: Name : SENSOR-SEAT TRACK POSITION-PASSENGER Color : DK. GRAY # of pins : 2 Pin Description Circuit Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 1186 1 PASSENGER SEAT POSITION SENSOR DATAR262 20WT/LB 2 PASSENGER SEAT POSITION SENSOR VOLTAGE R264 20VT/LB Component Location - 57 Sensor-Seat Weight-Left Front Component ID: 308 Component : SENSOR-SEAT WEIGHT-LEFT FRONT Connector: Name : SENSOR-SEAT WEIGHT-LEFT FRONT Color : BLACK # of pins : 3 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 1187 Pin Description Circuit 1 SEAT WEIGHT SENSOR GROUND R728 20LB/YL 2 SEAT WEIGHT LEFT FRONT SENSOR SIGNAL R717 20LG/DG 3 SEAT WEIGHT SENSOR 5 VOLT R701 20LG Component Location - 57 Sensor-Seat Weight-Left Rear Component ID: 309 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 1188 Component : SENSOR-SEAT WEIGHT-LEFT REAR Connector: Name : SENSOR-SEAT WEIGHT-LEFT REAR Color : BLACK # of pins : 3 Pin Description Circuit 1 SEAT WEIGHT SENSOR GROUND R728 20LB/YL 2 SEAT WEIGHT LEFT REAR SENSOR SIGNALR705 20LG/OR 3 SEAT WEIGHT SENSOR 5 VOLT R701 20LG Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 1189 Sensor-Seat Weight-Right Front Component ID: 310 Component : SENSOR-SEAT WEIGHT-RIGHT FRONT Connector: Name : SENSOR-SEAT WEIGHT-RIGHT FRONT Color : BLACK # of pins : 3 Pin Description Circuit Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 1190 1 SEAT WEIGHT SENSOR GROUND R728 20LB/YL 2 SEAT WEIGHT RIGHT FRONT SENSOR SIGNAL R718 20LB/DG 3 SEAT WEIGHT SENSOR 5 VOLT R701 20LG Component Location - 57 Sensor-Seat Weight-Right Rear Component ID: 311 Component : SENSOR-SEAT WEIGHT-RIGHT REAR Connector: Name : SENSOR-SEAT WEIGHT-RIGHT REAR Color : BLACK # of pins : 3 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 1191 Pin Description Circuit 1 SEAT WEIGHT SENSOR GROUND R728 20LB/YL 2 SEAT WEIGHT RIGHT REAR SENSOR SIGNAL R706 20LB/OR 3 SEAT WEIGHT SENSOR 5 VOLT R701 20LG Component Location - 57 Switch-Seat Belt-Driver Component ID: 355 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 1192 Component : SWITCH-SEAT BELT-DRIVER Connector: Name : SWITCH-SEAT BELT-DRIVER Color : BLACK # of pins : 2 Pin Description Circuit 1 DRIVER SEAT BELT SWITCH SENSE R57 20LG/GY 2 GROUND Z961 20BK/YL Component Location - 48 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 1193 Switch-Seat Belt-Passenger Component ID: 356 Component : SWITCH-SEAT BELT-PASSENGER Connector: Name : SWITCH-SEAT BELT-PASSENGER Color : WHITE # of pins : 2 Pin Description Circuit Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 1194 1 PASSENGER HALL EFFECT (+) R274 20LB/WT 2 PASSENGER HALL EFFECT (-) R272 20LB/VT Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder Ignition Switch Lock Cylinder: Service and Repair Key/Lock Cylinder Removal REMOVAL 1. Access and remove the Steering Column Control Module (SCCM) (3) from the steering column (2). 2. If equipped with Thatcham security (Export), remove the screws securing the cup (1) over the key cylinder. Remove the cup. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 1201 3. Remove the screw (1) fastening the SKREEM/WCM (2) to the lock cylinder housing (3). 4. Unhook the SKREEM/WCM (2) retainer fingers from the lock cylinder housing (3) and remove it. 5. Insert the key (2) and turn the key cylinder (3) to the RUN position. 6. Insert an appropriate tool into the slot (1) formed into the lock cylinder housing depressing the key cylinder retaining tab. 7. Pull the key cylinder and key straight out of the lock cylinder housing as one unit. 8. Using a Tamper-Proof Torx(R) Plus (five point) 30 bit, remove the two screws (1) fastening the lock cylinder housing (2) to the column. 9. Remove the lock cylinder housing from the steering column. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 1202 10. Remove the ignition module (2) mounting screw (1). 11. Pull the module (1) straight out and off the retaining tabs (2) located on the lock cylinder housing. Installation INSTALLATION NOTE: Ignition module must be installed prior to lock housing installation on column. Otherwise, the tilt lever will obstruct installation of ignition switch. 1. Ensure the ignition module is in the RUN position and the actuator shaft in the lock housing is in the RUN position. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 1203 2. Align the ignition module with the pin (3), actuator shaft and retaining tabs (2) located on the lock cylinder housing. Carefully install the module, snapping it into place over the retaining tabs. 3. Install the ignition module (2) mounting screw (1). Tighten the screw to 2 Nm (18 in. lbs.). NOTE: Ignition module needs to be installed on lock cylinder housing before housing installation to clear tilt lever. 4. Position the lock cylinder housing in the RUN position. 5. Align the lock cylinder housing (2) with the steering column. 6. Install the two screws (1) fastening the lock cylinder housing (2) to the column. Tighten the screws to 12 Nm (110 in. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 1204 7. Place the actuator in the lock cylinder housing to the RUN position (if not already there). 8. Insert the key into the key cylinder and turn the key cylinder to the RUN position. 9. Align the retaining tab on the key cylinder with the slot in the top of the lock cylinder housing. 10. Slide the key cylinder into the lock cylinder housing until the key cylinder retaining tab locks the cylinder into place. 11. Rotate the key back and forth (OFF to START), then remove and reinstall it, making sure the key cylinder and lock cylinder housing operate properly. 12. Slide the ring of the SKREEM/WCM (2) over the lock cylinder housing (3) and engage the retainer fingers in the recesses formed on the lock cylinder housing. 13. Install the screw (1) fastening the SKREEM/WCM (2) to the lock cylinder housing (3). Tighten the screw to 2.5 Nm (22 in. lbs.). 14. If equipped with Thatcham security (Export), install the cup (1) over the key cylinder and install the two mounting screws. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 1205 15. Install the Steering Column Control Module (SCCM) (3) and all components removed to access it. 16. Check operation of all steering column mounted components. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 1206 Ignition Switch Lock Cylinder: Service and Repair Housing-Lock Cylinder Removal REMOVAL 1. Access and remove the Steering Column Control Module (SCCM) (3) from the steering column (2). 2. If equipped with Thatcham security, remove the screws securing the cup (1) over the key cylinder. Remove the cup. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 1207 3. Remove the screw (1) fastening the SKREEM/WCM (2) to the lock cylinder housing (3). 4. Unhook the SKREEM/WCM (2) retainer fingers from the lock cylinder housing (3) and remove it. 5. Insert the key (2) and turn the key cylinder (3) to the RUN position. 6. Insert an appropriate tool into the slot (1) formed into the lock cylinder housing depressing the key cylinder retaining tab. 7. Pull the key cylinder and key straight out of the lock cylinder housing as one unit. 8. Using a Tamper-Proof Torx(R) Plus (five point) 30 bit, remove the two screws (1) fastening the lock cylinder housing (2) to the column. 9. Remove the lock cylinder housing from the steering column. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 1208 10. Remove the ignition module (2) mounting screw (1). 11. Pull the module (1) straight out and off the retaining tabs (2) located on the lock cylinder housing. Installation INSTALLATION NOTE: Ignition module must be installed prior to lock housing installation on column. Otherwise, the tilt lever will obstruct installation of ignition switch. 1. Ensure the ignition module is in the RUN position and the actuator shaft in the lock housing is in the RUN position. 2. Align the ignition module with the pin (3), actuator shaft and retaining tabs (2) located on the lock cylinder housing. Carefully install the module, snapping it into place over the retaining tabs. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 1209 3. Install the ignition module (2) mounting screw (1). Tighten the screw to 2 Nm (18 in. lbs.). NOTE: Ignition module needs to be installed on lock cylinder housing before housing installation to clear tilt lever. 4. Position the lock cylinder housing in the RUN position. 5. Align the lock cylinder housing (2) with the steering column. 6. Install the two screws (1) fastening the lock cylinder housing (2) to the column. Tighten the screws to 12 Nm (110 in. lbs.). 7. Place the actuator in the lock cylinder housing to the RUN position (if not already there). 8. Insert the key into the key cylinder and turn the key cylinder to the RUN position. 9. Align the retaining tab on the key cylinder with the slot in the top of the lock cylinder housing. 10. Slide the key cylinder into the lock cylinder housing until the key cylinder retaining tab locks the cylinder into place. 11. Rotate the key back and forth (OFF to START), then remove and reinstall it, making sure the key cylinder and lock cylinder housing operate Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 1210 properly. 12. Slide the ring of the SKREEM/WCM (2) over the lock cylinder housing (3) and engage the retainer fingers in the recesses formed on the lock cylinder housing. 13. Install the screw (1) fastening the SKREEM/WCM (2) to the lock cylinder housing (3). Tighten the screw to 2.5 Nm (22 in. lbs.). 14. If equipped with Thatcham security, install the cup (1) over the key cylinder and install the two mounting screws. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 1211 15. Install the Steering Column Control Module (SCCM) (3) and all components removed to access it. 16. Check operation of all steering column mounted components. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Neutral Safety Switch: Locations Component ID: 340 Component : SWITCH-CLUTCH INTERLOCK Connector: Name : SWITCH-CLUTCH INTERLOCK Color : BLACK # of pins : 3 Qualifier : (MTX) Pin Description Circuit 1 CLUTCH UPSTOP SWITCH SIGNAL T26 20DG/OR 2 GROUND Z925 20BK/OR 2 GROUND Z961 20BK/YL 3 CLUTCH INTERLOCK SIGNAL T141 20YL/RD Component Location - 44 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 1215 Component Location - 47 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 1216 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 1217 Neutral Safety Switch: Diagrams Component ID: 340 Component : SWITCH-CLUTCH INTERLOCK Connector: Name : SWITCH-CLUTCH INTERLOCK Color : BLACK # of pins : 3 Qualifier : (MTX) Pin Description Circuit 1 CLUTCH UPSTOP SWITCH SIGNAL T26 20DG/OR 2 GROUND Z925 20BK/OR 2 GROUND Z961 20BK/YL 3 CLUTCH INTERLOCK SIGNAL T141 20YL/RD Component Location - 44 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 1218 Component Location - 47 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 1219 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Technical Service Bulletins > Steering - ESP Lamp On Possible DTC C121A/C2205 Steering Angle Sensor: Technical Service Bulletins Steering - ESP Lamp On Possible DTC C121A/C2205 NUMBER: 08-010-07 GROUP: Vehicle Performance DATE: May 17, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: DTC's C121A / C2205 - Steering Angle Sensor - Not Initialized / Internal OVERVIEW: This bulletin involves selectively erasing and reprogramming the Steering Angle Sensor (SAS) with new software. MODELS: 2007 (JK) Wrangler 2007 (JS) Sebring 2007 (KA) Nitro 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to vehicles built on or before April 12, 2007 (MDH 0412XX). SYMPTOM/CONDITION: The vehicle operator may experience an illumination of the Electronic Stability Program (ESP) lamp on the vehicle instrument cluster. The ESP lamp illumination may be due to the following Diagnostic Trouble Codes (DTC's): C121A - Steering Angle Sensor Not Initialized C2205 - Steering Angle Sensor Internal This condition, and DTC's, may be intermittent. If the above DTC's occur during a drive cycle, then the ESP lamp will remain illuminated until the end of that drive cycle (key off). DIAGNOSIS: Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Technical Service Bulletins > Steering - ESP Lamp On Possible DTC C121A/C2205 > Page 1226 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 7.04 SPI or higher. The software release level is visible in the blue header at the top of the StarSCAN® screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. For instruction on setting up your StarSCAN® for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU (SAS) part number. Using the StarSCAN(R) at the "Home screen: a. Select "ECU View" b. Touch the screen to highlight the ECU (SAS) in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Technical Service Bulletins > Steering - ESP Lamp On Possible DTC C121A/C2205 > Page 1227 k. When the update is complete, select "OK". NOTE: Due to the ECU (SAS) programming procedure, a DTC may be set in other electronic modules within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Technical Service Bulletins > Steering - ESP Lamp On Possible DTC C121A/C2205 Steering Angle Sensor: Technical Service Bulletins Steering - ESP Lamp On Possible DTC C121A/C2205 NUMBER: 08-010-07 GROUP: Vehicle Performance DATE: May 17, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: DTC's C121A / C2205 - Steering Angle Sensor - Not Initialized / Internal OVERVIEW: This bulletin involves selectively erasing and reprogramming the Steering Angle Sensor (SAS) with new software. MODELS: 2007 (JK) Wrangler 2007 (JS) Sebring 2007 (KA) Nitro 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to vehicles built on or before April 12, 2007 (MDH 0412XX). SYMPTOM/CONDITION: The vehicle operator may experience an illumination of the Electronic Stability Program (ESP) lamp on the vehicle instrument cluster. The ESP lamp illumination may be due to the following Diagnostic Trouble Codes (DTC's): C121A - Steering Angle Sensor Not Initialized C2205 - Steering Angle Sensor Internal This condition, and DTC's, may be intermittent. If the above DTC's occur during a drive cycle, then the ESP lamp will remain illuminated until the end of that drive cycle (key off). DIAGNOSIS: Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Technical Service Bulletins > Steering - ESP Lamp On Possible DTC C121A/C2205 > Page 1233 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 7.04 SPI or higher. The software release level is visible in the blue header at the top of the StarSCAN® screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. For instruction on setting up your StarSCAN® for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU (SAS) part number. Using the StarSCAN(R) at the "Home screen: a. Select "ECU View" b. Touch the screen to highlight the ECU (SAS) in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Technical Service Bulletins > Steering - ESP Lamp On Possible DTC C121A/C2205 > Page 1234 k. When the update is complete, select "OK". NOTE: Due to the ECU (SAS) programming procedure, a DTC may be set in other electronic modules within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions Tire Pressure Sensor: Service Precautions CAUTION CAUTION: The use of tire sealants is strictly prohibited for vehicles equipped with the Tire Pressure Monitoring system. Tire sealants can clog tire pressure sensors. CAUTION: Any time a sensor is to be installed in a wheel, it is necessary to install a new sensor-to-wheel seal, metal washer and valve stem nut, to ensure air tight sealing. CAUTION: Tire pressure sensor valve stem caps and cores are specially designed for the sensors. Due to risk of corrosion, do not use a standard valve stem cap or core in a tire pressure sensor in place of the original equipment style sensor cap and core. CAUTION: When installing the valve core, be sure to tighten the core to specifications. Overtightening by a little as three or four inch pounds can damage the sensor. CAUTION: Do not attempt to install a tire pressure sensor in an aftermarket wheel. Use tire pressure sensors in original style factory wheels only. If aftermarket wheels are installed, and therefore do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. NOTE: TPM thresholds have been established for the original tire size equipped on the vehicle. Use original size tires only to maintain system accuracy. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Description Tire Pressure Sensor: Description and Operation Description DESCRIPTION On vehicles equipped with Tire Pressure Monitoring (TPM), one tire pressure sensor (6) is mounted to each wheel (5) in place of the traditional tire valve stem. Each sensor has an internal battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the sensor must be replaced. The TPM system operates on a 315 MHz radio frequency. The 315 MHz sensors can be easily identified by a white outline oval (black center) insignia (3) on the sensor body. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Description > Page 1241 The Export TPM system operates on a 433 MHz radio frequency. The 433 MHz sensors can be easily identified by either a solid white oval insignia (3) on the body or... ... a solid white oval insignia (3) with 433 printed in the center. The sensors are identical except for the oval insignia. The 433 MHz sensors can either have a black or grey sensor body. CAUTION: Although 315 MHz and 433 MHz sensors are identical in size and shape, they are not interchangeable. Always make sure the correct sensor is being used. NOTE: Sensors may be identified by valve stem cap color. From the factory, 315 MHz sensors have a gray valve stem cap while 433 MHz sensors have a black valve stem cap. Otherwise, once mounted inside a tire and wheel assembly you are not able to visually tell the difference between a 315 MHz and 433 MHz sensor. At that point, the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool may be used to identify the sensor frequency or the tire can be dismounted allowing visual inspection of the sensor body. The TPM sensors are designed for original style factory wheels. It is not recommended to install a tire pressure sensor in an aftermarket wheel (This could cause sealing and system performance issues). Do not attempt to install a tire pressure sensor in an aftermarket wheel. If aftermarket wheels are installed and do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Description > Page 1242 The serviceable components of the tire pressure sensor are: - Sensor-To-Wheel Seal (2) and Metal Washer (1) - Valve Stem Cap (4) - Valve Stem Core - Valve Stem Nut (with pressed-in washer) (3) NOTE: Any time a sensor is installed on a wheel, a new Sensor-To-Wheel Seal (2), Metal Washer (1) and Valve Stem Nut (3) must be installed to ensure air tight sealing. A service kit is available. The valve stem caps and cores are specifically designed for the tire pressure monitoring sensors. Although similar to standard valve stem caps and cores, they are different. The valve stem cap has a special seal inside to keep moisture and corrosion out. The valve stem core has a special nickel coating to protect from corrosion. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Description > Page 1243 Tire Pressure Sensor: Description and Operation Operation OPERATION The battery operated tire pressure sensor is both a transmitter and a receiver. The TPM sensor can be forced to transmit by using a special tool such as a TPM-RKE Analyzer, or from a transponder. The TPM-RKE Analyzer has the ability to change the sensor's operating mode to PARK MODE and to help diagnose a faulty TPM sensor. Using a TPM-RKE Analyzer can take up to a minute to force a transmission from a sensor. The TPM sensor can be in one of the following operating modes: - SLEEP MODE - This is the operating mode of a new TPM sensor. If placed on the vehicle as a road tire, the sensor will transmit once every 20 seconds when the vehicle is driven at speeds over 15 mph (24 km/h). Driving the vehicle continuously at this speed for more then 4 minutes will change the sensor state to DRIVE MODE. Stopping the vehicle for 20 minutes will change the sensor state to PARK MODE. If the vehicle is not moving, the sensor will only transmit on a pressure change greater then 1 psi (6.9 kPa). - PARK MODE - This is the correct operating mode when the vehicle is not moving. The sensor will transmit once every 13 hours to update the WCM, or will transmit on a 1 psi (6.9 kPa) delta change. The sensors will internally take a measurement of the tire pressure every minute to determine a change in tire pressure. - 30 BLOCK MODE - If the vehicle has been stopped for more then 20 minutes, or if the sensor's operating mode was forced to PARK MODE using a TPM-RKE Analyzer, the sensor's operating mode will transition from PARK MODE to 30 BLOCK MODE once the vehicle is driven over 15 mph. In this mode, the sensor will transmit once every 15 seconds when the vehicle is driven at speeds over 15 mph (24 km/h) for the first 30 transmissions. After about 8 minutes of continuous driving above 15 mph (24 km/h), the sensor's mode will change to DRIVE MODE. - DRIVE MODE - In this mode, the sensor will transmit once every minute when the vehicle is driven at speeds over 15 mph (24 km/h). At any time the vehicle speed drops below 15 mph, the sensor will not transmit. The sensor mode will still be in drive mode when the sensor reaches speeds over 15 mph (24 km/h), unless the vehicle has been stationary for more then 20 minutes. Each sensor's (transmitter) broadcast is uniquely coded so that the wireless control module (WCM) can monitor the state of each of the sensors on the four rotating road wheels. The WCM can automatically learn and store the sensor's ID while driving "within 10 minutes continuously above 15 mph (24 Km/h)" after a sensor has been replaced. The vehicle must be stationary for more then 20 minutes in order to initiate the learning sequence. The WCM can also learn the sensor's ID using the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool following the procedure listed in the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Removal Tire Pressure Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Remove wheel mounting nuts (3), then tire and wheel assembly (1). CAUTION: The cap used on this valve stem contains an O-ring seal to prevent contamination and moisture from entering the valve stem. Retain this valve stem cap for reuse. Do not substitute a regular valve stem cap in its place. CAUTION: The valve stem used on this vehicle is made of aluminum and the core is nickel plated brass. The original valve stem core must be reinstalled and not substituted with a valve stem core made of a different material. This is required to prevent corrosion in the valve stem caused by the different metals. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Removal > Page 1246 3. Dismount tire from wheel following tire changer manufacturers instructions while paying special attention to the following to avoid damaging the pressure sensor: a. When breaking the tire bead loose from the wheel rim, avoid using the Bead Breaker in the area of the sensor. That includes both front and rear beads of the tire. b. When preparing to dismount the tire from the wheel, carefully insert the mounting/dismounting tool at the valve stem ± 10°, then proceed to dismount the tire from the wheel. Use this process on both the upper and lower tire beads. 4. Remove sensor nut (3) retaining sensor to wheel. While removing nut, hold pressure against rear of metal valve stem to keep valve stem from pushing rearward, damaging antenna strap. 5. Remove sensor (1) from wheel (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Removal > Page 1247 Tire Pressure Sensor: Service and Repair Installation INSTALLATION NOTE: Before reinstalling an existing tire pressure sensor, replace seal (2) and metal washer (1) at base of sensor valve stem (6) to ensure proper sealing. 1. Wipe area clean around sensor/valve stem mounting hole in wheel (5). Make sure surface of wheel is not damaged. CAUTION: To avoid damaging sensor antenna strap (1), hold pressure against rear of metal valve stem (2) while sensor is inserted through wheel mounting hole and nut is installed. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Removal > Page 1248 2. Insert sensor (1) through wheel (2) as shown keeping pressure against rear of metal valve stem (See Arrow). Potted side of sensor is to be positioned toward wheel. Do not attempt to mount sensor otherwise, damage may occur. 3. Install sensor nut (with pressed-in washer) (3) by hand. NOTE: Before tightening sensor nut, push downward on sensor housing (2) in an attempt to make it flush with interior contour of wheel (1). 4. While holding sensor in position, tighten sensor nut to 8 Nm (71 in. lbs.). CAUTION: Over-torquing the sensor nut by as little as 12 Nm (106 in. lbs.) may result in sensor separation from the valve stem. Under this condition, the sensor may still function. However, the condition should be corrected immediately. 5. Mount tire on wheel following tire changer manufacturers instructions, paying special attention to the following to avoid damaging tire pressure sensor: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Removal > Page 1249 a. Rotating Wheel Tire Changers - Once the wheel is mounted to the changer, position the sensor valve stem (2) approximately 210° from the head of the changer (located at 1) in a clockwise direction before rotating the wheel (also in a clockwise direction) to mount the tire. Use this procedure on both the upper and lower tire beads. b. Rotating Tool Tire Changers - Position the wheel on the changer so that the sensor valve stem (1) is located approximately 210° clockwise from the installation end of the mounting/dismounting tool (2) once the tool is mounted for tire installation. Make sure the sensor is clear of the lower bead breaker area (3) to avoid damaging the sensor when the breaker rises. Rotate the tool (2) in a counterclockwise direction to mount the tire. Use this procedure on both the upper and lower tire beads. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Removal > Page 1250 6. Adjust air pressure to that listed on Tire Inflation Pressure Label (Placard) provided with vehicle (applied to driver's side B-pillar). Make sure original style and color valve stem cap is securely installed to keep moisture out of sensor. 7. Install tire and wheel assembly (1) on vehicle. Tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 8. Lower vehicle. 9. Perform one of the following to make the system learn the new sensor ID. a. Use the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool to program the WCM/SKREEM with the tire pressure sensor ID. This is part of the TPM Diagnostic Verification Test. b. Once the vehicle has remained stationary for more than 20 minutes, drive vehicle for a minimum of 10 minutes while maintaining a continuous speed above 15 mph (24 km/h). During this time, the system will learn the new sensor ID. This is part of the TPM Diagnostic Verification Test. NOTE: If a sensor cannot be trained, refer to appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Description and Operation Transmission Speed Sensor: Description and Operation VEHICLE SPEED SENSOR The Vehicle Speed Sensor (VSS) is a hall effect sensor mounted above the transaxle differential. The sensor is triggered by the ring gear teeth passing below it. The VSS pulse signal to the speedometer/odometer is monitored by the PCM speed control circuitry to determine vehicle speed and to maintain speed control set speed. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Removal Transmission Speed Sensor: Service and Repair Removal REMOVAL 1. Open hood. 2. Remove the air cleaner housing. 3. Disconnect the speed sensor connector. CAUTION: Clean area around speed sensor before removing to prevent dirt from entering the transaxle during speed sensor removal. 4. Remove speed sensor retaining bolt. 5. Remove speed sensor from transaxle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Removal > Page 1258 Transmission Speed Sensor: Service and Repair Installation INSTALLATION 1. Using a NEW O-ring, install the speed sensor to the transaxle. 2. Install the bolt and tighten to 7 Nm (60 in. lbs.). 3. Connect speed sensor connector. 4. Install the air cleaner housing. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Description and Operation > Description Heated Glass Element Switch: Description and Operation Description DESCRIPTION The switch for the rear window defogger (EBL) system (1) is located in the A/C-heater control (2) in the instrument panel center bezel (3). When the rear window defogger switch is pressed to the On position a request signal is sent to the cabin compartment node (CCN), which sends a message to the totally integrated power module (TIPM) to operate the EBL system. When the high side driver in the TIPM is energized, current is directed to the rear defogger grid lines and to the heated side view mirrors (when equipped). The grid lines heat the glass to help clear the surface of fog or frost. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Description and Operation > Description > Page 1264 Heated Glass Element Switch: Description and Operation Operation OPERATION An amber indicator will illuminate when the rear window defogger switch is activated. When activated, the switch sends a request signal to the cabin compartment node (CCN), which sends a message to the totally integrated power module (TIPM) to energize the internal EBL high side driver to provide battery current to the rear window defogger grid lines and to the heated side view mirrors, when equipped. NOTE: The EBL system turns off automatically after 10 minutes of initial operation. Each following activation cycle of the EBL system will last 5 minutes. The EBL system will automatically turn off after an initial programmed time interval of about 10 minutes as long as the ignition switch is in RUN. After the initial time interval has expired, if the rear window defogger switch is pressed to ON again during the same ignition cycle, the EBL system will automatically turn off after about 5 minutes. The EBL system will also turn off if the ignition switch is turned to any position other than RUN or by manually pressing the rear window defogger switch a second time. The rear window defogger switch is diagnosed using a scan tool. The rear window defogger switch and indicator cannot be adjusted or repaired. The A/C-heater control must be replaced if the rear window defogger switch or indicator is found inoperative or damaged. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Window-Driver Power Window Switch: Locations Switch-Power Window-Driver Component ID: 349 Component : SWITCH-POWER WINDOW-DRIVER Connector: Name : SWITCH-POWER WINDOW-DRIVER C1 Color : LT. GRAY # of pins : 6 Pin Description Circuit 1 MASTER WINDOW SWITCH LEFT REAR (UP)Q411 14OR/WT 2 MASTER WINDOW SWITCH RIGHT REAR (UP) Q412 14OR/LB 3 MASTER WINDOW SWITCH RIGHT REAR (DOWN) Q612 14OR/DB 4 MASTER WINDOW SWITCH LEFT REAR (DOWN) Q611 14OR/GY 5 MASTER WINDOW SWITCH PASSENGER (DOWN) Q26 14OR/GY 5 RIGHT FRONT WINDOW DRIVER (DOWN) Q22 14OR/VT 6 MASTER WINDOW SWITCH PASSENGER (UP) Q16 14OR/TN 6 RIGHT FRONT WINDOW DRIVER (UP) Q12 14OR/BR Component Location - 54 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Window-Driver > Page 1269 Connector: Name : SWITCH-POWER WINDOW-DRIVER C2 Color : LT. GRAY # of pins : 8 Pin Description Circuit 1-2 IGNITION SWITCH OUTPUT (RUN-ACC) F981 14PK/BR 3 GROUND Z961 20BK/YL 3 GROUND Z929 20BK/PK 4 GROUND Z928 14BK/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Window-Driver > Page 1270 5 WINDOW LOCK OUT SWITCH OUTPUT Q15 14OR/RD 6 LEFT FRONT WINDOW DRIVER (DOWN) Q21 14OR/WT 6 MASTER WINDOW SWITCH PASSENGER (DOWN) Q26 14OR/GY 7 LEFT FRONT WINDOW DRIVER (UP) Q11 14OR/LG 7 MASTER WINDOW SWITCH PASSENGER (UP) Q16 14OR/TN 8 DOOR LOCK SWITCH MUX P697 20LG/DG Component Location - 54 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Window-Driver > Page 1271 Power Window Switch: Locations Switch-Power Window-Left Rear Component ID: 350 Component : SWITCH-POWER WINDOW-LEFT REAR Connector: Name : SWITCH-POWER WINDOW-LEFT REAR Color : LT. GRAY # of pins : 6 Pin Description Circuit 1 MASTER WINDOW SWITCH LEFT REAR (DOWN) Q611 14OR/GY 2 LEFT REAR WINDOW DRIVER (DOWN) Q211 14TN/LB 3 LEFT REAR WINDOW DRIVER (UP) Q111 14TN/YL 4 MASTER WINDOW SWITCH LEFT REAR (UP)Q411 14OR/WT 5-6 WINDOW LOCK OUT SWITCH OUTPUT Q15 14OR/RD Component Location - 56 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Window-Driver > Page 1272 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Window-Driver > Page 1273 Power Window Switch: Locations Switch-Power Window-Passenger Component ID: 351 Component : SWITCH-POWER WINDOW-PASSENGER Connector: Name : SWITCH-POWER WINDOW-PASSENGER Color : LT. GRAY # of pins : 6 Pin Description Circuit 1 MASTER WINDOW SWITCH PASSENGER (DOWN) Q26 14OR/GY 2 RIGHT FRONT WINDOW DRIVER (DOWN) Q22 14OR/VT 2 LEFT FRONT WINDOW DRIVER (DOWN) Q21 14OR/WT 3 RIGHT FRONT WINDOW DRIVER (UP) Q12 14OR/BR 3 LEFT FRONT WINDOW DRIVER (UP) Q11 14OR/LG 4 MASTER WINDOW SWITCH PASSENGER (UP) Q16 14OR/TN 5-- 6 WINDOW LOCK OUT SWITCH OUTPUT Q15 14OR/RD Component Location - 54 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Window-Driver > Page 1274 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Window-Driver > Page 1275 Power Window Switch: Locations Switch-Power Window-Right Rear Component ID: 352 Component : SWITCH-POWER WINDOW-RIGHT REAR Connector: Name : SWITCH-POWER WINDOW-RIGHT REAR Color : LT. GRAY # of pins : 6 Pin Description Circuit 1 MASTER WINDOW SWITCH RIGHT REAR (DOWN) Q612 14OR/DB 2 RIGHT REAR WINDOW DRIVER (DOWN) Q212 14OR/VT 3 RIGHT REAR WINDOW DRIVER (UP) Q112 14OR/BR 4 MASTER WINDOW SWITCH RIGHT REAR (UP) Q412 14OR/LB 5-6 WINDOW LOCK OUT SWITCH OUTPUT Q15 14OR/RD Component Location - 56 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Window-Driver > Page 1276 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Window-Driver Power Window Switch: Diagrams Switch-Power Window-Driver Component ID: 349 Component : SWITCH-POWER WINDOW-DRIVER Connector: Name : SWITCH-POWER WINDOW-DRIVER C1 Color : LT. GRAY # of pins : 6 Pin Description Circuit 1 MASTER WINDOW SWITCH LEFT REAR (UP)Q411 14OR/WT 2 MASTER WINDOW SWITCH RIGHT REAR (UP) Q412 14OR/LB 3 MASTER WINDOW SWITCH RIGHT REAR (DOWN) Q612 14OR/DB 4 MASTER WINDOW SWITCH LEFT REAR (DOWN) Q611 14OR/GY 5 MASTER WINDOW SWITCH PASSENGER (DOWN) Q26 14OR/GY 5 RIGHT FRONT WINDOW DRIVER (DOWN) Q22 14OR/VT 6 MASTER WINDOW SWITCH PASSENGER (UP) Q16 14OR/TN 6 RIGHT FRONT WINDOW DRIVER (UP) Q12 14OR/BR Component Location - 54 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Window-Driver > Page 1279 Connector: Name : SWITCH-POWER WINDOW-DRIVER C2 Color : LT. GRAY # of pins : 8 Pin Description Circuit 1-2 IGNITION SWITCH OUTPUT (RUN-ACC) F981 14PK/BR 3 GROUND Z961 20BK/YL 3 GROUND Z929 20BK/PK 4 GROUND Z928 14BK/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Window-Driver > Page 1280 5 WINDOW LOCK OUT SWITCH OUTPUT Q15 14OR/RD 6 LEFT FRONT WINDOW DRIVER (DOWN) Q21 14OR/WT 6 MASTER WINDOW SWITCH PASSENGER (DOWN) Q26 14OR/GY 7 LEFT FRONT WINDOW DRIVER (UP) Q11 14OR/LG 7 MASTER WINDOW SWITCH PASSENGER (UP) Q16 14OR/TN 8 DOOR LOCK SWITCH MUX P697 20LG/DG Component Location - 54 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Window-Driver > Page 1281 Power Window Switch: Diagrams Switch-Power Window-Left Rear Component ID: 350 Component : SWITCH-POWER WINDOW-LEFT REAR Connector: Name : SWITCH-POWER WINDOW-LEFT REAR Color : LT. GRAY # of pins : 6 Pin Description Circuit 1 MASTER WINDOW SWITCH LEFT REAR (DOWN) Q611 14OR/GY 2 LEFT REAR WINDOW DRIVER (DOWN) Q211 14TN/LB 3 LEFT REAR WINDOW DRIVER (UP) Q111 14TN/YL 4 MASTER WINDOW SWITCH LEFT REAR (UP)Q411 14OR/WT 5-6 WINDOW LOCK OUT SWITCH OUTPUT Q15 14OR/RD Component Location - 56 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Window-Driver > Page 1282 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Window-Driver > Page 1283 Power Window Switch: Diagrams Switch-Power Window-Passenger Component ID: 351 Component : SWITCH-POWER WINDOW-PASSENGER Connector: Name : SWITCH-POWER WINDOW-PASSENGER Color : LT. GRAY # of pins : 6 Pin Description Circuit 1 MASTER WINDOW SWITCH PASSENGER (DOWN) Q26 14OR/GY 2 RIGHT FRONT WINDOW DRIVER (DOWN) Q22 14OR/VT 2 LEFT FRONT WINDOW DRIVER (DOWN) Q21 14OR/WT 3 RIGHT FRONT WINDOW DRIVER (UP) Q12 14OR/BR 3 LEFT FRONT WINDOW DRIVER (UP) Q11 14OR/LG 4 MASTER WINDOW SWITCH PASSENGER (UP) Q16 14OR/TN 5-- 6 WINDOW LOCK OUT SWITCH OUTPUT Q15 14OR/RD Component Location - 54 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Window-Driver > Page 1284 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Window-Driver > Page 1285 Power Window Switch: Diagrams Switch-Power Window-Right Rear Component ID: 352 Component : SWITCH-POWER WINDOW-RIGHT REAR Connector: Name : SWITCH-POWER WINDOW-RIGHT REAR Color : LT. GRAY # of pins : 6 Pin Description Circuit 1 MASTER WINDOW SWITCH RIGHT REAR (DOWN) Q612 14OR/DB 2 RIGHT REAR WINDOW DRIVER (DOWN) Q212 14OR/VT 3 RIGHT REAR WINDOW DRIVER (UP) Q112 14OR/BR 4 MASTER WINDOW SWITCH RIGHT REAR (UP) Q412 14OR/LB 5-6 WINDOW LOCK OUT SWITCH OUTPUT Q15 14OR/RD Component Location - 56 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Window-Driver > Page 1286 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 1287 Power Window Switch: Testing and Inspection DIAGNOSIS AND TESTING - POWER WINDOW SWITCH Remove the switch. Using an ohmmeter, test the window switch for continuity in all positions listed in the Continuity Table. Refer to the Power Window Switch Continuity table to determine if continuity is correct. To test the left front down and express down switch position, connect pin 4 to ground and pin 12 to a 12 volt source. Using a voltmeter, measure for voltage from pin 13 to ground. To test the right front down and express down switch position, connect pin 4 to ground and pin 12 to a 12 volt source. Using a voltmeter, measure for voltage from pin 3 to ground. If the correct results are not obtained, replace the switch. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Removal Power Window Switch: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the front door bolster. 3. Disconnect the electrical harness connectors. 4. With the bolster on the bench, gently pry in on the tabs of the mirror switch and push through the front of the cover and remove. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Removal > Page 1290 Power Window Switch: Service and Repair Installation INSTALLATION 1. Place the mirror switch in bolster opening and firmly snap into place. 2. Connect the electrical harness connectors. 3. Install the front door bolster. 4. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Description Wiper Switch: Description and Operation Description DESCRIPTION The right (wiper) multi-function switch is located on the right side of the steering column, just below the steering wheel. This switch is the primary control for the front and rear wiper and washer systems. The only visible components of the switch are the control stalk (1), control knob (2) and control sleeve (3) that extend through the steering column shrouds on the right side of the column. The remainder of the switch including its mounting provisions and electrical connection are concealed beneath the shrouds. The switch housing and controls (6) are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. A single screw (7) through a mounting tab integral to the back of the switch housing, and a slide tab integral to the bottom of the switch housing secure the switch to the mounting bracket integral to the clockspring (3). A single connector receptacle containing seven terminal pins is integral to the inboard end of the switch housing and is connected by a jumper wire harness (5) directly to the Steering Control Module (SCM), which is internal to the housing (2) of the left multi-function switch (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Description > Page 1296 The right (wiper) multi-function switch provides the vehicle operator with a control interface for the following wiper and washer system functions: - Continuous Front Wipers - The right multi-function switch control knob provides detent switching for two continuous front wipe modes, low speed or high speed. Intermittent Front Wipers - The right multi-function switch control knob provides detent switching for the intermittent front wipe mode with five minor detent delay interval positions. - Front Wiper Mist Mode - The right multi-function switch control stalk includes momentary switching of the front wiper motor low speed circuit to provide a mist mode features (sometimes referred to as pulse wipe), which allows the vehicle operator to momentarily operate the front wipers for one or more complete cycles. - Front Washer Mode - The right multi-function switch control stalk provides momentary switching for control of the front washer system operation. - Intermittent Rear Wipe Mode - The right multi-function switch control sleeve provides detent switching for a single fixed interval intermittent rear wiper mode. - Rear Washer Mode - The right multi-function switch control sleeve provides two momentary switch positions for control of rear washer system operation. The right multi-function switch cannot be adjusted or repaired. If any function of the switch is ineffective, or if the switch is damaged, the entire switch unit must be replaced. The clockspring (with the multi-function switch mounting bracket), the left multi-function switch (with the SCM), the right multi-function switch and the jumper wire harness are each available for separate service replacement. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Description > Page 1297 Wiper Switch: Description and Operation Operation OPERATION The right (wiper) multi-function switch uses a combination of resistor multiplexing and conventional switching to control the many functions and features it provides. The switch receives a clean ground from the Steering Control Module (SCM), then provides resistor multiplexed and conventional analog return outputs to the SCM to indicate the selected switch positions. The SCM then sends electronic switch status messages over a Local Interface Network (LIN) data bus to the Electromechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN), and the EMIC relays electronic wiper and washer switch request messages over the Controller Area Network (CAN) data bus to other electronic modules in the vehicle. If the SCM detects no inputs from the right multi-function switch, it transmits an electronic Signal Not Available (SNA) status message over the LIN data bus. The SNA status signals the EMIC to request other electronic modules to implement a failsafe mode of operation for the front and rear wiper systems. The failsafe mode will maintain the last selected front and rear wiper system operation for the remainder of the current ignition cycle, after which both wiper systems will default to OFF. The right multi-function switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, the most reliable, efficient and accurate means to diagnose this component requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Following are descriptions of how the right multi-function switch is operated to control the many front and rear wiper and washer system functions and features it provides: - Front Wiper Control - The control knob on the end of the right multi-function switch control stalk is rotated to one of the two continuous wiper detents, to one of five intermittent wiper detents, or to the OFF position to select the front wiper mode. The SCM reads the input from the right multi-function switch and sends electronic wiper switch status messages over the LIN data bus to the EMIC, which relays an electronic wiper switch request message over the CAN data bus to other electronic modules in the vehicle. - Front Wiper Mist Mode - The front wiper mist mode is requested when the right multi-function switch control stalk is depressed downward towards the floor to a momentary MIST position. The front wiper motor will continue to operate, one complete cycle at a time, for as long as the control stalk is held in this position. The SCM reads the resistor multiplexed input from the right multi-function switch and sends an electronic wiper switch status message over the LIN data bus to the EMIC, which relays an electronic wiper switch request message over the CAN data bus to other electronic modules in the vehicle. - Front Washer Control - The right multi-function switch control stalk is pulled rearward towards the steering wheel to a momentary WASH position to activate the washer pump/motor in the front washer mode. The washer pump/motor will continue to operate for as long as the control stalk is held in this position. The SCM reads the resistor multiplexed input from the right multi-function switch and sends an electronic washer switch status message over the LIN data bus to the EMIC, which relays an electronic washer switch request message over the CAN data bus to other electronic modules in the vehicle. - Rear Wiper Control - The rear wiper mode is selected when the right multi-function switch control sleeve is rotated to the fixed interval intermittent rear wipe detent position, or the OFF detent position. The SCM reads the input from the right multi-function switch and sends an electronic wiper switch status message over the LIN data bus to the EMIC, which relays an electronic wiper switch request message over the CAN data bus to other electronic modules in the vehicle. - Rear Washer Control - The right multi-function switch control sleeve is rotated to one of two momentary WASH positions, either fully forward or fully rearward, to activate the washer pump/motor in the rear washer mode. The washer pump/motor will continue to operate in the rear washer mode until the control sleeve is released. The SCM reads the input from the right multi-function switch and sends an electronic washer switch status message over the LIN data bus to the EMIC, which relays an electronic washer switch request message over the CAN data bus to other electronic modules in the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 1298 Wiper Switch: Testing and Inspection RIGHT MULTI-FUNCTION SWITCH WARNING: To avoid personal injury or death, on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, occupant classification system, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. The right multi-function switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the Steering Control Module (SCM) or the electronic controls or communication between other modules and devices that provide some features of the front and rear wiper and washer systems. The most reliable, efficient and accurate means to diagnose the SCM or the electronic controls and communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. 1. Remove the right multi-function switch from the integral mounting bracket on the right side of the clockspring. 2. Using an ohmmeter, test the resistance between the terminals of the switch as shown in the three Function Tests tables. For all functions except those of the control stalk the values should be either less than 100 ohms (switch CLOSED) or greater than 1 megohm (switch OPEN). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 1299 3. If the switch fails any of the tests, replace the ineffective right multi-function switch as required. If the switch tests okay, but the switch input to the Steering Control Module (SCM) remains incorrect, be certain to check for a short or open in the jumper harness between the right multi-function switch and the SCM. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Removal Wiper Switch: Service and Repair Removal REMOVAL WARNING: To avoid personal injury or death, on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, occupant classification system, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove both the upper and lower shrouds from the steering column. 3. Remove the screw (2) that secures the right multi-function switch (1) to the mounting bracket integral to the right side of the clockspring (3) on the steering column. 4. Slide the switch away from the clockspring far enough to disengage the slide tab on the bottom of the switch housing from the channel formation in the mounting bracket. 5. Disconnect the jumper wire harness connector (1) from the connector receptacle on the inboard end of the right multi-function switch (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Removal > Page 1302 6. Remove the switch from the clockspring (3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Removal > Page 1303 Wiper Switch: Service and Repair Installation INSTALLATION WARNING: To avoid personal injury or death, on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, occupant classification system, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the right multi-function switch (2) close enough to the mounting bracket (3) integral to the right side of the clockspring to reconnect the jumper wire harness connector (1) to the connector receptacle on the inboard side of the switch housing. 2. Align the slide tab on the bottom of the switch housing with the channel integral to the clockspring mounting bracket, then slide the switch into the bracket until it is firmly seated. 3. Install and tighten the screw (2) that secures the mounting tab on the back of the right multi-function switch (1) to the mounting bracket on the clockspring (3). 4. Reinstall the upper and lower shrouds onto the steering column. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Removal > Page 1304 5. Reconnect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Wheel Alignment Specifications Alignment: Specifications Wheel Alignment Specifications Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Wheel Alignment Specifications > Page 1310 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Wheel Alignment Specifications > Page 1311 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Wheel Alignment Specifications > Page 1312 Alignment: Specifications Curb Height Specifications CURB HEIGHT MEASUREMENT The wheel alignment is to be checked and all alignment adjustments made with the vehicle at its required curb height specification. Vehicle height is to be checked with the vehicle on a flat, level surface, preferably a vehicle alignment rack. The tires are to be inflated to the recommended pressure. All tires are to be the same size as standard equipment. Vehicle height is checked with the fuel tank full of fuel, and no passenger or luggage compartment load. Vehicle height is not adjustable. If the measurement is not within specifications, inspect the vehicle for bent or weak suspension components. Compare the parts tag on the suspect coil spring(s) to the parts book and the vehicle sales code, checking for a match. Once removed from the vehicle, compare the coil spring height to a correct new or known good coil spring. The heights should vary if the suspect spring is weak. NOTE: Prior to reading the curb height measurement, the front and rear of the vehicle must be jounced to settle the suspension. Induce jounce by pushing down on the center of the bumper (fascia), using care not to damage the vehicle, moving the vehicle up and down, gradually increasing the suspension travel with each stroke. Release the bumper at the bottom of each stroke, repeating this action several times. Perform this to both front and rear suspensions an equal amount of times. Measure curb height as follows: 1. Jounce the vehicle. Refer to above note. NOTE: On some vehicles it may be necessary to remove an engine belly pan in order to gain access to the lower control arm pivot bolt. 2. FRONT - On each side of the vehicle, measure the distance (2) from the lower control arm rear (vertical) pivot bolt head (1) to the floor or alignment rack/lift runway surface. It may be necessary to measure to the bottom of a straight edge (3), placed from lift runway to runway, to get an accurate measurement. 3. REAR - On each side of the vehicle, measure the distance (2) from the center of the outboard trailing arm-to-body mounting bolt (1) to the floor or Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Wheel Alignment Specifications > Page 1313 alignment rack/lift runway surface. 4. Compare the measurements to specifications listed in the following CURB HEIGHT SPECIFICATIONS chart. Maximum left-to-right differential is not to exceed 12.5 mm (0.5 in.). 5. If curb height is found to be out of specification and there is no sign of excessive body damage, curb height can be changed by replacing the applicable spring with a spring offering a different check load. Curb Height Specifications Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1314 Alignment: Description and Operation DESCRIPTION Vehicle wheel alignment is the positioning of all interrelated front and rear suspension angles. These angles affect the handling and steering of the vehicle when it is in motion. Proper wheel alignment is essential for efficient steering, good directional stability, and proper tire wear. The method of checking a vehicle's front and rear wheel alignment varies depending on the manufacturer and type of equipment used. The manufacturer's instructions should always be followed to ensure accuracy of the alignment, except when DaimlerChrysler Corporation's wheel alignment specifications differ. On this vehicle, the suspension angles that can be adjusted are as follows: Front - Camber (with cradle shift or service adjustment bolt package) - Caster (limited adjustment with cradle shift) - Toe Rear - Toe Check the wheel alignment and make all wheel alignment adjustments with the vehicle standing at its proper curb height specification. Curb height is the normal riding height of the vehicle. It is measured from a certain point on the vehicle to the ground or a designated area while the vehicle is sitting on a flat, level surface. Refer to Curb Height Measurement. Typical wheel alignment angles and measurements are described in the following paragraphs. CAMBER Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1315 Camber is the inward or outward tilt of the top of the tire and wheel assembly. Inward tilt (2) is known as negative camber. Outward tilt (1) is known as positive camber. Camber is measured in degrees of angle relative to a true vertical line. Camber is a tire wearing angle. - Excessive negative camber will cause tread wear at the inside of the tire. - Excessive positive camber will cause tread wear on the outside of the tire. CROSS CAMBER Cross camber is the difference between left and right camber. To achieve the cross camber reading, subtract the right side camber reading from the left. For example, if the left camber is -0.7° and the right camber is -0.5°, the cross camber would be -0.2° (-0.7 - (-0.5) = -0.7 + 0.5 = -0.2). CASTER Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1316 Caster is the forward or rearward tilt of the steering knuckle in reference to the position of the upper and lower ball joints. Caster is measured in degrees of angle relative to a true vertical center line. This line is viewed from the side of the tire and wheel assembly. - Forward tilt (upper ball joint ahead of lower) results in a negative caster angle. - Rearward tilt (upper ball joint trailing lower) results in a positive caster angle. Although caster does not affect tire wear, a caster imbalance between the two front wheels may cause the vehicle to lead to the side with the least positive caster. CROSS CASTER Cross caster is the difference between left and right caster. To achieve the cross caster reading, subtract the right side caster reading from the left. For example, if the left caster is 2.5° and the right caster is 2.7°, the cross caster would be -0.2° (2.5 - 2.7 = -0.2). TOE Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1317 Toe is the inward or outward angle of the wheels as viewed from above the vehicle. - Toe-in (1) is produced when the front edges of the wheels on the same axle are closer together than the rear edges. - Toe-out (2) is produced when the front edges of the wheels on the same axle are farther apart than the rear edges. Toe-in and toe-out can occur at the front wheels and the rear wheels. Toe is measured in degrees or inches. The measurement identifies the amount that the front of the wheels point inward (toe-in) or outward (toe-out). Toe is measured at the spindle height. Zero toe means the front and rear edges of the wheels on the same axle are equal distant. TOE-OUT ON TURNS Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1318 Toe-out on turns (1), sometimes referred to as Ackerman Steering, is the relative positioning of the front wheels while steering through a turn. This compensates for each front wheel's turning radius. As the vehicle encounters a turn, the outboard wheel must travel in a larger radius circle than the inboard wheel. The steering system is designed to make each wheel follow its particular radius circle. To accomplish this, the front wheels must progressively toe outward as the steering is turned from center. This eliminates tire scrubbing and undue tire wear when steering a vehicle through a turn. DYNAMIC TOE PATTERN Dynamic toe pattern is the inward and outward toe movement of the front and rear tires through the suspension's jounce and rebound travel. As the vehicle's suspension moves up and down, the toe pattern varies. Toe pattern is critical in controlling the directional stability of the vehicle while in motion. Front and rear dynamic toe pattern is preset by the factory at the time the vehicle is assembled. It is not necessary to check or adjust front or rear dynamic toe pattern when doing a normal wheel alignment. The only time dynamic toe pattern needs to be checked or adjusted is if the frame of the vehicle has been damaged. STEERING AXIS INCLINATION (S.A.I.) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1319 Steering axis inclination (1) is the angle between a true vertical line starting at the center of the tire at the road contact point and a line drawn through the center of the upper ball joint (or strut) and the lower ball joint. S.A.I. is built into the vehicle and is not an adjustable angle. If S.A.I. is not within specifications, a bent or damaged suspension component may be the cause. INCLUDED ANGLE (I.A.) Included angle (3) is the sum of the S.A.I. angle (1) plus or minus the camber angle (2), depending on whether or not the wheel has positive or negative camber. If camber is positive, add the camber angle to the S.A.I angle. If camber is negative, subtract the camber angle from the S.A.I. angle. Included angle is not adjustable, but can be used to diagnose a frame misalignment or bent suspension component (spindle, strut). THRUST ANGLE Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1320 Thrust angle is the averaged direction the rear wheels are pointing in relation to the vehicle's center line. The presence of negative or positive thrust angle causes the rear tires to track improperly to the left or right of the front tires (dog tracking). - Negative thrust angle means the rear tires are tracking to the left of the front tires. - Positive thrust angle means the rear tires are tracking to the right of the front tires. Improper tracking can cause undue tire wear, a lead or pull and a crooked steering wheel. Excessive thrust angle can usually be corrected by adjusting the rear wheel toe so that each wheel has one-half of the total toe measurement. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1321 Alignment: Testing and Inspection SUSPENSION AND STEERING Suspension And Steering (Part 1) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1322 Suspension And Steering (Part 2) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1323 Suspension And Steering (Part 3) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment Alignment: Service and Repair Wheel Alignment WHEEL ALIGNMENT PRE-WHEEL ALIGNMENT INSPECTION Before any attempt is made to change or correct the wheel alignment, the following inspection and necessary corrections must be made to the vehicle to ensure proper alignment. 1. Verify the fuel tank is full of fuel. If the fuel tank is not full, the reduction in weight will affect the curb height of the vehicle and the alignment specifications. 2. The passenger and luggage compartments of the vehicle should be free of any load that is not factory equipment. 3. Check the tires on the vehicle. The tires are to be inflated to the recommended air pressure. All tires must be the same size and in good condition with approximately the same tread wear. 4. Check the front tire and wheel assemblies for excessive radial runout. 5. Inspect all suspension component fasteners for looseness and proper torque. 6. Inspect the lower front ball joints and all steering linkage for looseness and any sign of wear or damage. 7. Inspect the rubber bushings on all the suspension components for signs of wear or deterioration. If any bushings show signs of wear or deterioration, they should be replaced prior to aligning the vehicle. 8. Check vehicle curb height to verify it is within specifications. WHEEL ALIGNMENT SETUP 1. Position the vehicle on an alignment rack. 2. Install all required alignment equipment on the vehicle, per the alignment equipment manufacturer's instructions. On this vehicle, a four-wheel alignment is recommended. NOTE: Prior to reading the vehicle's alignment readouts, the front and rear of vehicle should be jounced. Induce jounce (rear first, then front) by grasping the center of the bumper and jouncing each end of vehicle an equal number of times. The bumper should always be released when vehicle is at the bottom of the jounce cycle. 3. Read the vehicle's current front and rear alignment settings. Compare the vehicle's current alignment settings to the vehicle specifications for camber, caster and toe-in. REAR CAMBER Rear camber settings on this vehicle are determined at the time the vehicle is designed, by the location of the vehicle's suspension components. This is referred to as Net Build. The result is no required adjustment of camber after the vehicle is built or when servicing the suspension components. Thus, when performing a wheel alignment, rear camber is not considered an adjustable angle. CAUTION: Do not attempt to adjust the vehicle's wheel alignment by heating or bending any of the suspension components. FRONT CAMBER AND CASTER Front camber and caster settings on this vehicle are determined at the time the vehicle is designed, by the location of the vehicle's suspension components. This is referred to as Net Build. The result is no required adjustment of camber and caster after the vehicle is built or when servicing the suspension components. Thus, when performing a wheel alignment, caster and camber are not normally considered adjustable angles but some adjustment can be made. Camber and caster should be checked to ensure they meet vehicle specifications. If individual front camber or caster is found not to meet alignment specifications, each can be adjusted by shifting the front crossmember or by using an available service adjustment bolt package. If an adjustment bolt package installation is necessary, inspect the suspension components for any signs of damage or bending first. CAUTION: Do not attempt to adjust the vehicle's wheel alignment by heating or bending any of the suspension components. ADJUSTMENT BY SHIFTING CROSSMEMBER CAUTION: Always use care when shifting crossmember to avoid damaging other components on the vehicle. 1. Loosen the four bolts fastening the front crossmember to the frame just enough to allow movement of the crossmember. 2. Loosen the bolts fastening the fore/aft crossmember to the frame just enough to allow movement of the crossmember. CAUTION: When shifting the front crossmember, keep in mind that the front and rear engine mounts are attached to the front crossmember and fore/aft crossmember and should be inspected following the crossmember shift to make sure they are properly aligned. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment > Page 1326 3. Shift front crossmember as necessary (See following tables) to bring camber or caster into specifications. When shifting crossmember, use care not to move other angles (camber or caster) that are within specifications, out of specifications. Front Camber Adjustment By Shifting Crossmember Front Caster Adjustment By Shifting Crossmember 4. Tighten all previously loosened fasteners (bolts) securing the crossmember to the vehicle to specifications. 5. Jounce the rear, then front of the vehicle an equal amount of times. 6. Measure camber and caster. If camber and caster are within specifications, proceed to TOE. If camber cannot be brought into specifications, perform the CAMBER ADJUSTMENT BOLT PACKAGE INSTALLATION below. CAMBER ADJUSTMENT BOLT PACKAGE INSTALLATION The camber adjustment bolt package contains new bolts and nuts for attaching the strut clevis bracket to the steering knuckle. The bolts contained in the package are slightly undersize allowing for movement between the strut clevis bracket and the steering knuckle. The movement allowed by the undersize bolts provide approximately two degrees of camber adjustment per side of the vehicle. To install and adjust the camber adjustment bolt package, follow the procedure below. 7. Raise the vehicle until its tires are not supporting the weight of the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment > Page 1327 8. Remove the wheel mounting nuts (3), then the front tire and wheel assembly (1). CAUTION: The strut clevis-to-knuckle attaching bolt shanks are serrated and must not be turned during removal. Remove the nuts while holding the bolts stationary, then tap the bolts out using a punch. 9. Remove the original upper bolt (1) and nut (3) attaching the strut clevis bracket (2) to the knuckle (5). 10. Install a bolt from the adjustment package into the hole where the original bolt was removed. Install the bolt as indicated. 11. Install a nut provided in adjustment package on the replacement bolt. Tighten the nut until it's snug, but still allows the knuckle to slide in the clevis bracket. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment > Page 1328 12. Remove the original lower bolt (6) and nut (4) attaching the strut clevis bracket (2) to the knuckle (5). 13. Install a bolt from the adjustment package into the bottom hole of the strut clevis bracket. Install the bolt as indicated. 14. Install a nut provided in adjustment package on the replacement bolt. Tighten the nut until it's snug, but still allows the knuckle to slide in the clevis bracket. 15. Install the tire and wheel assembly (1). Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 16. Perform the above procedure to opposite strut as required. 17. Lower the vehicle and jounce the front and rear of the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment > Page 1329 18. Adjust the front camber to the preferred setting by pushing or pulling on the top of the tire. When camber is set to specifications, tighten the upper and lower strut clevis-to-knuckle attaching bolt nuts (3, 4) enough to hold the adjustment. Again jounce the front and rear of the vehicle, then verify the camber settings. 19. Tighten the front strut clevis-to-knuckle attaching bolt nuts (3, 4) to 84 Nm (62 ft. lbs.). 20. Once camber is within specifications, adjust toe to meet the preferred specification setting. Refer to FRONT TOE within this wheel alignment service procedure. TOE 1. Center the steering wheel and lock it in place using a steering wheel clamp. NOTE: When setting toe, make sure to set rear toe to the preferred specifications before setting front toe to the preferred specifications REAR TOE NOTE: Perform the following at each rear wheel as necessary. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment > Page 1330 2. While holding the cam bolt head (3) stationary, loosen the toe link mounting cam bolt nut (1). 3. Rotate the cam bolt head (3) left or right until the rear wheel toe for that rear wheel is set to the preferred specification. 4. While holding the cam bolt head (3) stationary, tighten the toe link mounting cam bolt nut (1) to 25 Nm (18 ft. lbs.). FRONT TOE NOTE: Perform the following at each front wheel as necessary. CAUTION: Do not twist the inner tie rod-to-steering gear boot (bellows) while turning the inner tie rod during front toe adjustment. It may be necessary to remove the clamp where the boot meets the inner tie rod. 5. Loosen the tie rod adjusting jam nut (1). Grasp the inner tie rod (3) and rotate it one way or the other until the front wheel toe is set to the preferred specification. 6. Tighten the tie rod adjusting jam nut to of 75 Nm (55 ft. lbs.). 7. Make sure the inner tie rod-to-steering gear boot is not twisted. If removed, reinstall the clamp where the boot meets the inner tie rod. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment > Page 1331 8. Remove the steering wheel clamp. 9. Remove the alignment equipment. 10. Road test the vehicle to verify the steering wheel is straight and the vehicle does not pull or wander. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment > Page 1332 Alignment: Service and Repair Curb Height Measurement CURB HEIGHT MEASUREMENT The wheel alignment is to be checked and all alignment adjustments made with the vehicle at its required curb height specification. Vehicle height is to be checked with the vehicle on a flat, level surface, preferably a vehicle alignment rack. The tires are to be inflated to the recommended pressure. All tires are to be the same size as standard equipment. Vehicle height is checked with the fuel tank full of fuel, and no passenger or luggage compartment load. Vehicle height is not adjustable. If the measurement is not within specifications, inspect the vehicle for bent or weak suspension components. Compare the parts tag on the suspect coil spring(s) to the parts book and the vehicle sales code, checking for a match. Once removed from the vehicle, compare the coil spring height to a correct new or known good coil spring. The heights should vary if the suspect spring is weak. NOTE: Prior to reading the curb height measurement, the front and rear of the vehicle must be jounced to settle the suspension. Induce jounce by pushing down on the center of the bumper (fascia), using care not to damage the vehicle, moving the vehicle up and down, gradually increasing the suspension travel with each stroke. Release the bumper at the bottom of each stroke, repeating this action several times. Perform this to both front and rear suspensions an equal amount of times. Measure curb height as follows: 1. Jounce the vehicle. Refer to above note. NOTE: On some vehicles it may be necessary to remove an engine belly pan in order to gain access to the lower control arm pivot bolt. 2. FRONT - On each side of the vehicle, measure the distance (2) from the lower control arm rear (vertical) pivot bolt head (1) to the floor or alignment rack/lift runway surface. It may be necessary to measure to the bottom of a straight edge (3), placed from lift runway to runway, to get an accurate measurement. 3. REAR - On each side of the vehicle, measure the distance (2) from the center of the outboard trailing arm-to-body mounting bolt (1) to the floor or Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment > Page 1333 alignment rack/lift runway surface. 4. Compare the measurements to specifications listed in the following CURB HEIGHT SPECIFICATIONS chart. Maximum left-to-right differential is not to exceed 12.5 mm (0.5 in.). 5. If curb height is found to be out of specification and there is no sign of excessive body damage, curb height can be changed by replacing the applicable spring with a spring offering a different check load. Curb Height Specifications Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL SYSTEM PRESSURE Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1338 Fuel Pressure: Testing and Inspection *CHECKING THE FUEL DELIVERY SYSTEM For a complete wiring diagram refer to Diagrams/Electrical. Diagnostic Test 1. CHECKING THE FUEL PUMP OPERATION Turn the ignition on. NOTE: Diagnose and repair any fuel pump control circuit or relay DTCs before continuing with this test. With a scan tool, actuate the fuel pump control to ON (100%). NOTE: It may be necessary to use a mechanics stethoscope in the next step. Listen for fuel pump operation at the fuel tank. The fuel pump should operate smoothly, without excessive noise. If necessary, compare to a known good vehicle of similar year, make, and model. NOTE: If the pump has excessive noise or grinding, the pump should be replaced. caution: Stop all actuation tests before continuing. Is the fuel pump operating when actuated? Yes - Go to 2 No - Go to 7 2. CHECKING THE FUEL PRESSURE Turn the ignition off. WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in personal injury or death. Install a fuel pressure gauge on the fuel rail. Turn the ignition on. With the scan tool, actuate the fuel pump relay control. Observe the fuel pressure gauge. NOTE: The fuel pressure specification is 407 KPa ± 34 KPa (59 psi ± 5 psi). caution: Stop all actuation tests before continuing. Select the conclusion that best matches the result of the test: Fuel pressure is within the stated specification - Test complete. Fuel pressure is below the stated specification - Go to 3 Fuel pressure is above the stated specification - Replace the fuel filter/pressure regulator. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1339 - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 3. RESTRICTED FUEL SUPPLY LINE Turn the ignition off. WARNING: The fuel system is under a constant pressure, even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in personal injury or death. Raise vehicle on hoist, and disconnect the fuel pressure line at the fuel pump module. Install special 5/16 fuel line adapter tool #6539 between disconnected fuel line and the fuel pump module. Attach a fuel pressure test gauge to the T fitting on tool #6539. Turn the ignition on. With the scan tool, actuate the fuel pump relay control. Observe the fuel pressure gauge. NOTE: Fuel pressure specification is 407 KPa ± 34 KPa (59 psi ± 5 psi). caution: Stop all actuation tests before proceeding. Is the fuel pressure within specification? Yes - Repair or replace fuel supply line as necessary. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 4 4. SADDLE FUEL TANK Is the vehicle equipped with a saddle type fuel tank? Yes - Go to 5 No - Go to 6 5. FUEL TANK SIPHON HOSE OR FUEL LINE RESTRICTED OR DAMAGED Turn the ignition off. WARNING: The fuel system is under a constant pressure, even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in personal injury or death. Gain access to the fuel pump module and the fuel tank module. Inspect the fuel line and siphon hose between the fuel pump module and the fuel tank module. Look for disconnected or damaged lines and hoses. Inspect the fuel pressure regulator for damage or a condition that might cause a fuel flow problem. Make sure that it is seated in the module properly. Were any problems found? Yes - Repair as necessary. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1340 - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 6 6. FUEL PUMP INLET STRAINER Turn the ignition off. WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in personal injury or death. Remove the fuel pump module and inspect the fuel inlet strainer for damage or a condition that might cause a fuel flow problem. Were any problems found? Yes - Replace the Fuel Pump Inlet Strainer. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Replace the Fuel Pump Module. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 7. FUEL PUMP GROUND CIRCUIT OPEN OR HIGH RESISTANCE Turn the ignition off. Disconnect the Fuel Pump Module harness connector. Using a 12 volt test light connected to 12 volts, check the Fuel Pump Motor Ground circuit at the Fuel Pump Module harness connector. NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated and bright? Yes - Replace the Fuel Pump Module. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Repair the Fuel Pump Ground circuit for an open circuit or high resistance. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by manufacturer Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal Air Filter Element: Service and Repair Removal REMOVAL 1. Turn lock retainers (5) and remove fresh air inlet (2) from air cleaner housing (1). 2. Disconnect intake air temperature sensor connector (4). 3. Remove air inlet tube (5) from air cleaner housing (1). 4. Unfasten clasps (2) on sides of air cleaner housing cover. 5. Pull air cleaner cover (1) aside. 6. Remove filter element (3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal > Page 1349 7. If necessary, clean the inside of the air cleaner housing (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal > Page 1350 Air Filter Element: Service and Repair Installation INSTALLATION 1. Install new filter element. 2. Place cover over air cleaner housing. Snap clasps (2) in place. 3. Install air inlet tube (5). 4. Connect intake air temperature sensor connector (4). 5. Install fresh air inlet (2) on air cleaner housing (1) and lock retainers (5). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE PROCEDURE 1. Remove lower rear seat cushion. 2. Remove the fuel pump module cover. 3. Disconnect the electrical connector for fuel pump module. 4. Start and run engine until it stalls. 5. Attempt restarting engine until it will no longer run. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Page 1355 6. Turn ignition key to OFF position. 7. Disconnect negative battery cable. 8. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory. The scan tool must be used to erase a DTC. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications DESCRIPTION The 2.4 Liter (148 cu. in.) in-line four cylinder engine is a double over head camshaft design with mechanical lash tappets and four valves per cylinder design. This engine is NOT free-wheeling; meaning that the pistons will contact the valves in the event of a timing chain failure. The cylinders are numbered from front of the engine to the rear. The firing order is 1-3-4-2. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications SPARK PLUGS Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Removal Spark Plug: Service and Repair Removal 2.0/2.4L 1. Disconnect the negative battery cable. 2. Disconnect the electrical connectors from ignition coils. 3. Remove the ignition coil mounting bolt. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Removal > Page 1364 4. Twist the ignition coil then pull straight up. 5. Remove the spark plug using a quality socket with a rubber or foam insert. 6. Inspect the spark plug condition. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Removal > Page 1365 Spark Plug: Service and Repair Installation 2.0/2.4L Special care should be used when installing spark plugs in the cylinder head spark plug wells. Be sure the plugs do not drop into the wells, damage to the electrodes can occur. Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap. Overtightening can also damage the cylinder head. 1. To avoid cross threading, start the spark plug into the cylinder head by hand. 2. Tighten spark plugs to 17.5±2 Nm (13±2 ft. lbs.). 3. Install ignition coil on to spark plug. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Removal > Page 1366 4. Tighten coil mounting bolt. Tighten to 9 Nm (79.5 in. lbs.). 5. Connect electrical connectors and lock. 6. Connect the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Pressure Metric ................................................................................................................................................... ...................................................... 1172-1551 kPa Standard .............................................................. ............................................................................................................................................ 170-225 psi Compression should not be less than 1034 kPa (150 psi) and not vary more than 25 percent from cylinder to cylinder. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1370 Compression Check: Testing and Inspection CYLINDER COMPRESSION PRESSURE TEST The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine reaches normal operating temperature. Select a route free from traffic and other forms of congestion, observe all traffic laws, and accelerate through the gears several times briskly. 3. Remove engine cover. 4. Disconnect coil electrical connectors and remove coils. 5. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing indicators fouled, hot, oily, etc. Record cylinder number of spark plug for future reference. 6. Disconnect injector electrical connectors. 7. Be sure throttle blade is fully open during the compression check. 8. Insert compression gauge adaptor 8116 or the equivalent, into the #1 spark plug hole in cylinder head. Connect the 0-500 psi (Blue) pressure transducer CH7059 with cable adaptors to the DRBIII(R). 9. Crank engine until maximum pressure is reached on gauge. Record this pressure as #1 cylinder pressure. 10. Repeat the previous step for all remaining cylinders. 11. Compression should not be less than 1034 kPa (150 psi) and not vary more than 25 percent from cylinder to cylinder. 12. If one or more cylinders have abnormally low compression pressures, repeat the compression test. 13. If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem in the cylinder in question. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Valve Lash Intake ................................................................................................................................................... .............................. 17 - 23 mm (0.006 - 0.009 in.) Exhaust ................................................................ .............................................................................................................. 27 - 33 mm (0.010 - 0.012 in.) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 1374 Valve Clearance: Adjustments MEASURING VALVE LASH 1. Remove engine cover. 2. Remove cylinder head cover. 3. Rotate camshaft so lobes are vertical (1). 4. Check clearance using feeler gauges. 5. Repeat for all tappets and record readings. 6. If clearance was too small, go to the clearance to small procedure.Clearance to Small. 7. If clearance was too large, go to the clearance to large procedure.Clearance to Large. Clearance to Small Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 1375 1. Remove camshafts. 2. Specification - clearance = change 3. Decrease bucket thickness by change figure. 4. Install camshafts. 5. Verify that valve lash is correct. Clearance to Large 1. Remove camshafts. 2. Clearance - specification = change. 3. Increase bucket thickness by change figure. 4. Install camshafts. 5. Verify that valve lash is correct. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Timing Component Alignment Marks > Component Information > Locations Timing Component Alignment Marks: Locations ^ Verify that the crankshaft sprocket keyway is at the 9 o'clock position. ^ Align camshaft timing marks (3) so they are parallel to the cylinder head and aligned each other as shown. ^ Install timing chain so plated links on chain align with timing marks on camshaft sprockets (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Timing Component Alignment Marks > Component Information > Locations > Page 1379 ^ Align timing mark on the crankshaft sprocket (2) with the plated link (3) on the timing chain. Position chain so slack will be on the tensioner side. ^ Rotate the crankshaft CLOCKWISE two complete revolutions until the crankshaft is repositioned at the TDC position with the key way at the 9 o'clock position. ^ Verify that the camshafts timing marks (3) are in the proper position. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Timing Component Alignment Marks > Component Information > Locations > Page 1380 ^ Install the balancer and verify that balancer mark (2) and cover mark (1) are aligned. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams Drive Belt: Diagrams Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 1384 Drive Belt: Description and Operation GAS ENGINE The accessory drive belt (2) is a serpentine type belt that is driven by the crankshaft pulley (6). The belt drives the A/C compressor, generator (3), power steering pump (1) and water pump (7). Belt tension is maintained by an automatic belt tensioner (8). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 1385 Drive Belt: Testing and Inspection ACCESSORY DRIVE BELT VISUAL DIAGNOSIS When diagnosing serpentine accessory drive belts, small cracks that run across the ribbed surface of the belt from rib to rib (1), are considered normal. These are not a reason to replace the belt. However, cracks running along a rib (not across) (2) are not normal. Any belt with cracks running along a rib must be replaced. Also replace the belt if it has excessive wear, frayed cords or severe glazing. Refer to ACCESSORY DRIVE BELT DIAGNOSIS CHART for further belt diagnosis. NOISE DIAGNOSIS Noises generated by the accessory drive belt are most noticeable at idle. Before replacing a belt to resolve a noise condition, inspect all of the accessory drive pulleys for contamination, alignment, glazing, or excessive end play. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 1386 Accessory Drive Belt Diagnosis Chart (Part 1) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 1387 Accessory Drive Belt Diagnosis Chart (Part 2) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Procedures Drive Belt: Procedures CLEANING Clean all foreign debris from belt pulley grooves. The belt pulleys must be free of oil, grease, and coolants before installing the drive belt. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Procedures > Page 1390 Drive Belt: Removal and Replacement Removal GAS ENGINE 1. Using a wrench, rotate accessory drive belt tensioner (8) counterclockwise until accessory drive belt (2) can be removed from pulleys (5 and 9). 2. Remove accessory drive belt (2). Installation GAS ENGINE NOTE: When installing drive belt on the pulleys, make sure that belt is properly routed and all V-grooves make proper contact with pulley grooves. 1. Install the accessory drive belt (2) around all the pulleys except for the generator pulley (3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Procedures > Page 1391 2. Using a wrench, rotate accessory drive belt tensioner (8) counterclockwise until accessory drive belt (2) can be installed on the generator pulley (3). Release spring tension onto accessory drive belt (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal Air Filter Element: Service and Repair Removal REMOVAL 1. Turn lock retainers (5) and remove fresh air inlet (2) from air cleaner housing (1). 2. Disconnect intake air temperature sensor connector (4). 3. Remove air inlet tube (5) from air cleaner housing (1). 4. Unfasten clasps (2) on sides of air cleaner housing cover. 5. Pull air cleaner cover (1) aside. 6. Remove filter element (3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal > Page 1398 7. If necessary, clean the inside of the air cleaner housing (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal > Page 1399 Air Filter Element: Service and Repair Installation INSTALLATION 1. Install new filter element. 2. Place cover over air cleaner housing. Snap clasps (2) in place. 3. Install air inlet tube (5). 4. Connect intake air temperature sensor connector (4). 5. Install fresh air inlet (2) on air cleaner housing (1) and lock retainers (5). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Description and Operation Cabin Air Filter: Description and Operation DESCRIPTION Some models are equipped with a particulate air filter (1) that helps purify the outside air entering the HVAC housing. The filter is mounted in the passenger compartment, behind the glove box bin. The filter should be replaced at least once a year or every 24,000 km (15,000 miles) and checked if heating-A/C system performance seems lower than expected. The particulate air filter is labeled with an arrow (2) to indicate the direction of air flow through the filter. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair > Procedures Cabin Air Filter: Procedures REMOVAL NOTE:LHD model shown in illustrations. RHD model similar. NOTE:Illustration shown with instrument panel removed for clarity. 1. Remove the glove box bin. 2. Disengage the two retaining tabs (1) that secure the particulate air filter cover (2) to the passenger side of the HVAC housing (3) and remove the cover. 3. Remove the particulate air filter (1) from the HVAC housing (2) by pulling the filter element straight out of the housing. INSTALL NOTE:The particulate air filter is labeled with an arrow to indicate air flow direction through the filter. Make sure to properly install the particulate air filter. Failure to properly install the filter will result in the need to replace the filter sooner than required by design. NOTE:LHD model shown in illustrations. RHD model similar. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair > Procedures > Page 1405 1. Install the particulate air filter (1) into the filter opening in the HVAC housing (2). Insert the particulate air filter directly into the housing with the arrow on the filter pointing to the floor. 2. Position the particulate air filter cover (2) to the HVAC housing (3) and engage the two retaining tabs (1) that secure the cover to the housing. Make sure the retaining tabs are fully engaged. 3. Install the glove box bin Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair > Procedures > Page 1406 Cabin Air Filter: Removal and Replacement Removal REMOVAL NOTE: LHD model shown in illustrations. RHD model similar. NOTE: Illustration shown with instrument panel removed for clarity. 1. Remove the glove box bin. 2. Disengage the two retaining tabs (1) that secure the particulate air filter cover (2) to the passenger side of the HVAC housing (3) and remove the cover. 3. Remove the particulate air filter (1) from the HVAC housing (2) by pulling the filter element straight out of the housing. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair > Procedures > Page 1407 Installation INSTALLATION NOTE: The particulate air filter is labeled with an arrow to indicate air flow direction through the filter. Make sure to properly install the particulate air filter. Failure to properly install the filter will result in the need to replace the filter sooner than required by design. NOTE: LHD model shown in illustrations. RHD model similar. 1. Install the particulate air filter (1) into the filter opening in the HVAC housing (2). Insert the particulate air filter directly into the housing with the arrow on the filter pointing to the floor. 2. Position the particulate air filter cover (2) to the HVAC housing (3) and engage the two retaining tabs (1) that secure the cover to the housing. Make sure the retaining tabs are fully engaged. 3. Install the glove box bin. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE PROCEDURE 1. Remove lower rear seat cushion. 2. Remove the fuel pump module cover. 3. Disconnect the electrical connector for fuel pump module. 4. Start and run engine until it stalls. 5. Attempt restarting engine until it will no longer run. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Page 1412 6. Turn ignition key to OFF position. 7. Disconnect negative battery cable. 8. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory. The scan tool must be used to erase a DTC. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Description and Operation Fuel Pump Pickup Filter: Description and Operation DESCRIPTION The fuel pump inlet strainer is a non-serviceable part. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair > Engine Oil and Filter Change Oil Filter: Service and Repair Engine Oil and Filter Change ENGINE OIL AND FILTER CHANGE WARNING: New or used engine oil can be irritating to the skin. Avoid prolonged or repeated skin contact with engine oil. Contaminants in used engine oil, caused by internal combustion, can be hazardous to your health. Thoroughly wash exposed skin with soap and water. Do not wash skin with gasoline, diesel fuel, thinner, or solvents, health problems can result. Do not pollute, dispose of used engine oil properly. Contact your dealer or government agency for location of collection center in your area. Change engine oil at mileage and time intervals described in the Maintenance Schedule. 1. Run engine until achieving normal operating temperature. 2. Position the vehicle on a level surface and turn engine off. 3. Remove oil fill cap. 4. Raise vehicle on hoist. 5. Place a suitable oil collecting container under oil pan drain plug (2). 6. Remove oil pan drain plug (2) or and allow oil to drain into collecting container. Inspect drain plug threads for stretching or other damage. Replace drain plug and gasket if damaged. 7. Remove oil filter (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair > Engine Oil and Filter Change > Page 1420 8. Install oil pan drain plug (2) and tighten drain plug to 28 Nm (20 ft. lbs.). 9. Install new oil filter (1). 10. Lower vehicle and fill crankcase with specified type and amount of engine oil. 11. Install oil fill cap. 12. Start engine and inspect for leaks. 13. Stop engine and inspect oil level. OIL FILTER SPECIFICATION All engines are equipped with a high quality full-flow, disposable type oil filter. Replace oil filter with a Mopar(R) or the equivalent. USED ENGINE OIL DISPOSAL Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to the WARNING listed above. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair > Engine Oil and Filter Change > Page 1421 Oil Filter: Service and Repair Removal REMOVAL CAUTION: When servicing the oil filter, avoid deforming the filter can by installing the remove/install tool band strap against the can to base lock seam. The lock seam joining the can to the base is reinforced by the base plate. 1. Using a suitable filter wrench, turn oil filter (1) counterclockwise to remove. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair > Engine Oil and Filter Change > Page 1422 Oil Filter: Service and Repair Installation INSTALLATION 1. Clean and check filter mounting surface. The surface must be smooth, flat and free of debris or pieces of gasket. 2. Lubricate new oil filter gasket. 3. Screw oil filter (1) on until the gasket contacts base. Tighten to 14 Nm (11 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Removal Coolant Line/Hose: Service and Repair Removal REMOVAL The water pump inlet tube (2) connects the water pump to the coolant adapter. This tube is sealed by an O-ring and held in place by fasteners to the water pump housing. 1. Drain cooling system. 2. Remove the coolant adapter and secondary thermostat. 3. Raise and support vehicle. 4. Remove inlet tube mounting nuts (1). 5. Remove inlet tube (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Removal > Page 1428 Coolant Line/Hose: Service and Repair Installation INSTALLATION 1. Inspect the O-ring for damage before installing the tube. Replace O-ring as necessary. 2. Lubricate O-rings with soapy water. 3. Install new water inlet gasket between tube and water pump housing (2). 4. Position water pump inlet tube (3) on water pump housing (2). Hand tighten nuts to aide in tube alignment. 5. Install secondary thermostat and coolant adapter. 6. Tighten coolant tube nuts (1) to 24 Nm (212 in. lbs.). 7. Fill cooling system. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service Precautions > Warning Hose/Line HVAC: Service Precautions Warning WARNING WARNING: The A/C system contains refrigerant under high pressure. Repairs should only be performed by qualified service personnel. Serious or fatal injury may result from improper service procedures. WARNING: Avoid breathing the refrigerant and refrigerant oil vapor or mist. Exposure may irritate the eyes, nose, and/or throat. Wear eye protection when servicing the A/C refrigerant system. Serious eye injury can result from direct contact with the refrigerant. If eye contact occurs, seek medical attention immediately. WARNING: Do not expose the refrigerant to open flame. Poisonous gas is created when refrigerant is burned. An electronic leak detector is recommended. Serious or fatal injury may result from improper service procedures. WARNING: If accidental A/C system discharge occurs, ventilate the work area before resuming service. Large amounts of refrigerant released in a closed work area will displace the oxygen and cause suffocation and serious or fatal injury. WARNING: The evaporation rate of R-134a refrigerant at average temperature and altitude is extremely high. As a result, anything that comes in contact with the refrigerant will freeze. Always protect the skin or delicate objects from direct contact with the refrigerant. WARNING: The R-134a service equipment or the vehicle refrigerant system should not be pressure tested or leak tested with compressed air. Some mixtures of air and R-134a have been shown to be combustible at elevated pressures. These mixtures are potentially dangerous, and may result in fire or explosion causing property damage and serious or fatal injury. WARNING: The engine cooling system is designed to develop internal pressures up to 145 kilopascals (21 pounds per square inch). Do not remove or loosen the coolant pressure cap, cylinder block drain plugs, radiator drain, radiator hoses, heater hoses, or hose clamps while the engine cooling system is hot and under pressure. Allow the vehicle to cool for a minimum of 15 minutes before opening the cooling system for service. Failure to observe this warning can result in serious burns from the heated engine coolant. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service Precautions > Warning > Page 1433 Hose/Line HVAC: Service Precautions Caution CAUTION CAUTION: Never add R-12 to a refrigerant system designed to use R-134a. Do not use R-12 equipment or parts on an R-134a A/C system. These refrigerants are not compatible and damage to the A/C system will result. CAUTION: Never use R-12 refrigerant oil in an A/C system designed to use R-134a refrigerant oil. These refrigerant oils are not compatible and damage to the A/C system will result. CAUTION: The use of A/C system sealers may result in damage to A/C refrigerant recovery/evacuation/recharging equipment and/or A/C system. Many federal, state/provincial and local regulations prohibit the recharge of A/C systems with known leaks. DaimlerChrysler recommends the detection of A/C system leaks through the use of approved leak detectors and fluorescent leak detection dyes. Vehicles found with A/C system sealers should be treated as contaminated and replacement of the entire A/C refrigerant system is recommended. A/C systems found to be contaminated with A/C system sealers, A/C stop-leak products or seal conditioners voids the warranty for the A/C system. CAUTION: Recover the refrigerant before opening any fitting or connection. Open the fittings with caution, even after the system has been discharged. Never open or loosen a connection before recovering the refrigerant. CAUTION: The internal parts of the A/C system will remain stable as long as moisture-free refrigerant and refrigerant oil is used. Abnormal amounts of dirt, moisture or air can upset the chemical stability. This may cause operational troubles or even serious damage if present in more than very small quantities. Before disconnecting a component, clean the outside of the fittings thoroughly to prevent contamination from entering the refrigerant system. Keep service tools and the work area clean. Do not open the refrigerant system or uncap a replacement component until you are ready to service the system. Immediately after disconnecting a component from the refrigerant system, seal the open fittings with a cap or plug. This will prevent contamination from entering the A/C system. CAUTION: Refrigerant oil will absorb moisture from the atmosphere if left uncapped. Do not open a container of refrigerant oil until you are ready to use it. Replace the cap on the oil container immediately after using. Store refrigerant oil only in a clean, airtight, and moisture-free container. CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system. Failure to follow this caution will result in serious A/C compressor damage. CAUTION: Do not overcharge the refrigerant system. Overcharging will cause excessive compressor head pressure and can cause compressor noise and A/C system failure. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line Hose/Line HVAC: Description and Operation A/C Discharge Line DESCRIPTION NOTE: A/C discharge line for gasoline engine shown in illustration. A/C discharge line for diesel engine similar. The A/C discharge line (1) is the refrigerant line that carries refrigerant from the A/C compressor to the A/C condenser and includes the high side service port (2) and a fitting (3) for the A/C pressure transducer (4). NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C discharge line has no serviceable parts except for the metal gaskets (5) and rubber O-ring seals (6) and the high side service port valve core. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals and gaskets must be replaced whenever the A/C discharge line is removed. The A/C discharge line cannot be repaired and must be replaced if found to be leaking or damaged. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line > Page 1436 Hose/Line HVAC: Description and Operation A/C Liquid Line DESCRIPTION The A/C liquid line (1) is the refrigerant line that carries refrigerant from the A/C condenser to the A/C evaporator. The A/C liquid line contains the low side service port (2) and the variable A/C orifice tube. The A/C liquid line is only serviced as an assembly with the upper A/C suction line (3). NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C liquid/suction line assembly has no serviceable parts except for the metal gaskets (4), rubber O-ring seals (5) and the low side service port valve core. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals and gaskets must be replaced whenever the A/C liquid/suction line assembly is removed. The A/C liquid/suction line assembly cannot be repaired and must be replaced if found to be leaking or damaged, or if an internal failure of the A/C compressor has occurred. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line > Page 1437 Hose/Line HVAC: Description and Operation A/C Suction Line DESCRIPTION The A/C suction line is serviced in two sections. The upper section of the A/C suction line (1) is the refrigerant line that carries refrigerant from the A/C evaporator to the A/C accumulator. The lower section of the A/C suction line (2) carries refrigerant from the A/C accumulator to the A/C compressor. The upper portion of the A/C suction line is only serviced as an assembly with the A/C liquid line (5). NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The lower A/C suction line and the A/C liquid/suction line assembly has no serviceable parts except for the rubber O-ring seals (3), metal gaskets (4) and the low side service port valve core. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals and gaskets must be replaced whenever the lower A/C suction line and/or the A/C liquid/suction line assembly is removed. The lower A/C suction line and the A/C liquid/suction line assembly cannot be repaired and must be replaced if found to be leaking or damaged. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line > Page 1438 Hose/Line HVAC: Description and Operation Plumbing Description DESCRIPTION The A/C refrigerant lines and hoses are used to carry the refrigerant between the various A/C system components. The refrigerant lines and hoses for the R-134a A/C system consist of a barrier-hose design with a nylon tube sandwiched between rubber layers. The nylon tube helps to contain the R-134a refrigerant, which has a small molecular structure. The ends of the refrigerant lines are made from lightweight aluminum and braze-less fittings. Any kinks or sharp bends in the refrigerant lines and hoses will reduce the capacity of the entire A/C system and can reduce the flow of refrigerant within the system. Operation OPERATION High pressures are produced in the refrigerant system when the A/C compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. Depending on vehicle, model and market application, refrigerant lines are connected to each other or other A/C system components with block-type or quick-connect type fittings. To ensure the integrity of the refrigerant system, flat gaskets and O-rings are used to seal the refrigerant system connections. The refrigerant lines and hoses cannot be repaired and must be replaced if leaking or damaged. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line Hose/Line HVAC: Service and Repair A/C Discharge Line Removal REMOVAL WARNING: Review safety precautions and warnings before performing this procedure. Failure to follow the warnings and cautions could result in possible personal injury or death. NOTE: It is not necessary to completely remove the front fascia for A/C discharge line service. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant system. 3. Raise and support the vehicle. 4. Remove the splash shield from the right side frame rail. 5. Remove the nut (1) that secures the A/C discharge line (2) to the A/C compressor (3). 6. Disconnect the A/C discharge line from the A/C compressor and remove and discard the O-ring seal and gasket. 7. Install plugs in, or tape over the opened discharge line fitting and the compressor port. 8. Lower the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 1441 9. Remove the upper radiator closure panel and carefully pull the top of the fascia forward to gain access to the A/C discharge line (3). 10. Reach down through the opening between the radiator and the front fascia and disconnect the wire harness connector (1) from the A/C pressure transducer (2). 11. Remove the nut (5) that secures the A/C discharge line to the right side of the A/C condenser (4). 12. Disconnect the A/C discharge line from the A/C condenser and remove and discard the O-ring seal and gasket. 13. Install plugs in, or tape over the discharge line fitting and the condenser port. 14. If necessary, remove the A/C pressure transducer from the A/C discharge line. Installation INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system. Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 1442 1. If removed, install the A/C pressure transducer (2) onto the A/C discharge line (3). Tighten the A/C pressure transducer securely. 2. Position the A/C discharge line into the engine compartment. 3. Remove the tape or plugs from the discharge line fitting and the condenser port. 4. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the discharge line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 5. Reach down through the opening between the radiator and the front fascia and connect the A/C discharge line to the A/C condenser (4). 6. Install the nut (5) that secures the A/C discharge line to the A/C condenser. Tighten the nut to 5 Nm (44 in. lbs.). 7. Connect the wire harness connector (1) to the A/C pressure transducer. 8. Install the upper radiator closure panel. 9. Raise and support the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 1443 10. Remove the tape or plugs from the discharge line fitting and the compressor port. 11. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the discharge line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 12. Connect the A/C discharge line (2) to the A/C compressor (3). 13. Install the nut (1) that secures the A/C discharge line to the A/C compressor. Tighten the nut to 20 Nm (15 ft. lbs.). 14. Install the splash shield onto the right side frame rail. 15. Lower the vehicle. 16. Reconnect the negative battery cable. CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system. Failure to follow this caution will result in serious A/C compressor damage. 17. Evacuate the refrigerant system. 18. Adjust the refrigerant oil level. 19. Charge the refrigerant system. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 1444 Hose/Line HVAC: Service and Repair A/C Liquid Line Removal REMOVAL WARNING: Review safety precautions and warnings before performing this procedure. Failure to follow the warnings and cautions could result in possible personal injury or death. NOTE: The A/C liquid line is only serviced as an assembly with the upper A/C suction line. NOTE: LHD model shown in illustrations. RHD model similar. NOTE: Illustration shown with front fascia removed for clarity. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant system. 3. Raise and support the vehicle. 4. Remove the A/C accumulator. 5. Reach up through the opening in the bottom of the front fascia located in the right front corner of the vehicle and remove the nut (3) that secures the A/C liquid line (1) to the A/C condenser (2). 6. Disconnect the A/C liquid line from the A/C condenser and remove and discard the O-ring seal and gasket. 7. Install plugs in, or tape over the opened refrigerant line fittings and the condenser and accumulator ports. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 1445 8. Lower the vehicle. 9. Remove the three nuts (1) that secure the heat shield (3) to the studs (2) located on the dash panel in the engine compartment and remove the heat shield. NOTE: It is only necessary to position the engine coolant reservoir and the power steering fluid reservoir out of the way. Draining of the coolant and brake fluid is not required when servicing the washer bottle. 10. Remove the windshield washer reservoir. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 1446 11. Remove the nut (1) that secures the refrigerant line retaining bracket (2) to the right front strut tower (5). 12. On RHD models, disengage the retainers that secure the power brake booster vacuum supply hose to the dash panel and position the vacuum line out of the way. 13. Remove the bolt (3) that secures the A/C liquid and suction line assembly (4) to the A/C evaporator (6). 14. Disconnect the A/C liquid and suction line assembly from the A/C evaporator and remove and discard the dual-plane seals. 15. Install plugs in, or tape over the opened refrigerant line fittings and the evaporator ports. 16. Remove the A/C liquid and suction line assembly from the engine compartment. Installation INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system. Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. CAUTION: The A/C liquid line must be replaced if an internal failure of the A/C compressor has occurred. Failure to replace the A/C liquid line can prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: LHD model shown in illustrations. RHD model similar. 1. Position the A/C liquid and suction line assembly (4) into the engine compartment. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 1447 2. Remove the tape or plugs from the refrigerant line fittings and the evaporator ports. 3. Lubricate the rubber O-rings on new dual-plane seals with clean refrigerant oil and install the seals onto the liquid and suction line fittings. Use only the specified seals as they are made of special materials compatible to the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Connect the A/C liquid and suction line assembly to the A/C evaporator (6). 5. Install the bolt (3) that secures the A/C liquid and suction line assembly to the A/C evaporator. Tighten the bolt to 12 Nm (105 in. lbs.). 6. On RHD models, engage the retainers that secure the power brake booster vacuum supply hose to the dash panel. 7. Install the nut (1) that secures the refrigerant line bracket (2) to the right front strut tower (5). Tighten the nut to 4.5 Nm (40 in. lbs.). 8. Install the windshield washer reservoir, power steering reservoir and the engine coolant reservoir. 9. Position the heat shield (3) onto the studs (2) located on the dash panel in the engine compartment. 10. Install the three nuts (1) that secure the heat shield to the dash panel. Tighten the nuts to 1 Nm (10 in. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 1448 NOTE: Illustration shown with front fascia removed for clarity. 11. Raise and support the vehicle. 12. Remove the tape or plugs from the liquid line fitting and the condenser port. 13. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the liquid line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 14. Reach up through the opening in the bottom of the front fascia and connect the A/C liquid line (1) to the A/C condenser (2) and install the retaining nut (3). Tighten the nut to 5 Nm (44 in. lbs.). 15. Install the A/C accumulator. 16. Lower the vehicle. 17. Reconnect the negative battery cable. CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system. Failure to follow this caution will result in serious A/C compressor damage. 18. Evacuate the refrigerant system. 19. Adjust the refrigerant oil level. 20. Charge the A/C system. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 1449 Hose/Line HVAC: Service and Repair A/C Suction Line Removal REMOVAL WARNING: Review safety precautions and warnings before performing this procedure. Failure to follow the warnings and cautions could result in possible personal injury or death. NOTE: The A/C suction line is serviced in two sections. The upper section of the A/C suction line is the refrigerant line that carries refrigerant from the A/C evaporator to the A/C accumulator. The lower section of the A/C suction line carries refrigerant from the A/C accumulator to the A/C compressor. NOTE: LHD model shown in illustrations. RHD model similar. Upper A/C Suction Line NOTE: The upper portion of the A/C suction line is only serviced as an assembly with the A/C liquid line. NOTE: Illustration shown with front fascia removed for clarity. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant system. 3. Raise and support the vehicle. 4. Remove the A/C accumulator. 5. Reach up through the opening in the bottom of the front fascia located in the right front corner of the vehicle and remove the nut (3) that secures the A/C liquid line (1) to the A/C condenser (2). 6. Disconnect the A/C liquid line from the A/C condenser and remove and discard the O-ring seal and gasket. 7. Install plugs in, or tape over the opened refrigerant line fittings and the condenser and accumulator ports. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 1450 8. Lower the vehicle. 9. Remove the three nuts (1) that secure the heat shield (3) to the studs (2) located on the dash panel in the engine compartment and remove the heat shield. NOTE: It is only necessary to position the engine coolant reservoir and the power steering fluid reservoir out of the way. Draining of the coolant and brake fluid is not required when servicing the washer bottle. 10. Remove the windshield washer reservoir. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 1451 11. Remove the nut (1) that secures the refrigerant line retaining bracket (2) to the right front strut tower (5). 12. On RHD models, disengage the retainers that secure the power brake booster vacuum supply hose to the dash panel and position the vacuum line out of the way. 13. Remove the bolt (3) that secures the A/C liquid and suction line assembly (4) to the A/C evaporator (6). 14. Disconnect the A/C liquid and suction line assembly from the A/C evaporator and remove and discard the dual-plane seals. 15. Install plugs in, or tape over the opened refrigerant line fittings and the evaporator ports. 16. Remove the A/C liquid and suction line assembly from the engine compartment. Lower A/C Suction Line 17. Disconnect and isolate the negative battery cable. 18. Recover the refrigerant from the refrigerant system. 19. Raise and support the vehicle. 20. Remove the right front wheel. 21. Remove the three push-pin retainers (1) and three screws (2) that secure the front portion of the right front wheelhouse splash shield (3) to body (4) and position the front of the wheelhouse splash shield out of the way to gain access to the A/C accumulator. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 1452 22. Remove the nut (2) that secures the lower A/C suction line (3) to the A/C accumulator (1). 23. Disconnect the lower A/C suction line from the A/C accumulator and remove and discard the O-ring seal and gasket. 24. Install plugs in, or tape over the opened suction line fitting and the accumulator port. 25. Remove the nut (1) that secures the lower A/C suction line (2) to the A/C compressor (3). 26. Disconnect the lower A/C suction line from the A/C compressor and remove and discard the O-ring seal and gasket. 27. Install plugs in, or tape over the opened suction line fitting and the compressor port. 28. Remove the lower A/C suction line from the engine compartment. Installation INSTALLATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 1453 CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system. Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: LHD model shown in illustrations. RHD model similar. Upper A/C Suction Line 1. Position the A/C liquid and suction line assembly (4) into the engine compartment. 2. Remove the tape or plugs from the refrigerant line fittings and the evaporator ports. 3. Lubricate the rubber O-rings on new dual-plane seals with clean refrigerant oil and install the seals onto the liquid and suction line fittings. Use only the specified seals as they are made of special materials compatible to the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Connect the A/C liquid and suction line assembly to the A/C evaporator (6). 5. Install the bolt (3) that secures the A/C liquid and suction line assembly to the A/C evaporator. Tighten the bolt to 12 Nm (105 in. lbs.). 6. On RHD models, engage the retainers that secure the power brake booster vacuum supply hose to the dash panel. 7. Install the nut (1) that secures the refrigerant line bracket (2) to the right front strut tower (5). Tighten the nut to 4.5 Nm (40 in. lbs.). 8. Install the windshield washer reservoir, power steering reservoir and the engine coolant reservoir. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 1454 9. Position the heat shield (3) onto the studs (2) located on the dash panel in the engine compartment. 10. Install the three nuts (1) that secure the heat shield to the dash panel. Tighten the nuts to 1 Nm (10 in. lbs.). NOTE: Illustration shown with front fascia removed for clarity. 11. Raise and support the vehicle. 12. Remove the tape or plugs from the liquid line fitting and the condenser port. 13. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the liquid line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 14. Reach up through the opening in the bottom of the front fascia and connect the A/C liquid line (1) to the A/C condenser (2) and install the retaining nut (3). Tighten the nut to 5 Nm (44 in. lbs.). 15. Install the A/C accumulator. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 1455 16. Lower the vehicle. 17. Reconnect the negative battery cable. 18. Evacuate the refrigerant system. 19. Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 20. Charge the A/C system. Lower A/C Suction Line 21. Position the lower A/C suction line (2) into the engine compartment. 22. Remove the tape or plugs from the suction line fitting and the compressor port. 23. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and new gasket onto the suction line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 24. Connect the lower A/C suction line to the A/C compressor (3). 25. Install the nut (1) that secures the A/C suction line to the A/C compressor. Tighten the nut to 20 Nm (15 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 1456 26. Remove the tape or plugs from the suction line fitting and the accumulator port. 27. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and new gasket onto the suction line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 28. Connect the lower A/C suction line (3) to the A/C accumulator (1). 29. Install the nut (2) that secures the lower A/C suction line to the A/C accumulator. Tighten the nut to 5 Nm (44 in. lbs.). 30. Reposition the front of the right front wheel house splash shield (3) to the body (4) and install the three push-pin retainers (1) and the three screws (2). Tighten the screws securely. 31. Install the right front wheel. 32. Lower the vehicle. 33. Reconnect the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 1457 CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system. Failure to follow this caution will result in serious A/C compressor damage. 34. Evacuate the refrigerant system. 35. Adjust the refrigerant oil level. 36. Charge the A/C system. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler Power Steering Line/Hose: Service and Repair Fluid Cooler Removal REMOVAL NOTE: Before proceeding, refer to STEERING WARNING. 1. Siphon as much fluid as possible from the power steering fluid reservoir. 2. Raise and support the vehicle. 3. Remove the front fascia. 4. Remove the hose clamps (6) attaching the fluid return hose (7) to the power steering fluid cooler line. Separate the return hose from the cooler line (5). 5. Remove the two cooler mounting screws (4). 6. Remove the cooler tubes from the clips on the side of the frame rail. 7. Remove the cooler lines (5) from the vehicle. Installation INSTALLATION 1. Install the cooler tubes in the clips on the side of the frame rail. 2. Install the fluid cooler mounting screws (4) to the support. Tighten the screws to 8 Nm (71 in. lbs.). 3. Install the fluid return hose (7) on the power steering fluid cooler lines (5). Install the hose clamp (6) on the hose past the bead formed into the end of the cooler tube and secure in place. 4. Install the front fascia. 5. Lower the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler > Page 1462 6. Fill and bleed the power steering system. 7. Check for leaks. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler > Page 1463 Power Steering Line/Hose: Service and Repair Hose-Pressure Removal GAS ENGINE NOTE: Before proceeding, refer to STEERING WARNING. 1. Siphon as much fluid as possible from the power steering fluid reservoir. 2. Remove the engine appearance cover. 3. Remove the pressure Hose (3) at the pump pressure port (5). 4. Remove the pressure hose routing bracket bolt (2) at the upper mount (8). 5. All except 2.4L Engine with All-Wheel-Drive - Remove the pressure hose routing clamp bolt (1) at the exhaust manifold. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler > Page 1464 6. 2.4L Engine with All-Wheel-Drive - Remove the pressure hose routing clamp bolt (1) at the exhaust manifold. 7. Raise and support the vehicle. 8. Remove the return hose (1) at the return tube (2). 9. Remove the return tube (1) at the steering gear (3). 10. Remove the pressure hose (2) at the steering gear (3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler > Page 1465 11. Remove the fasteners (1) securing the power steering hose routing clamps (2) to the crossmember. 12. Remove the power steering pressure hose from the vehicle. Installation GAS ENGINE CAUTION: Power steering fluid hoses must remain away from the exhaust system, driveshafts, vehicle components and any unfriendly surface that can possibly damage the hoses. 1. Using a lint free towel, wipe clean the open power steering hose end and the power steering pump port. Replace any used O-rings with new. Lubricate the O-ring with power steering fluid. 2. Install the power steering pressure hose into the engine compartment from below. 3. Install the fasteners (1) securing the power steering hose routing clamps (2) to the crossmember. Tighten the screws to 8 Nm (71 in. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler > Page 1466 4. Install the pressure hose (2) at the gear (3). Tighten the tube nut to 32 Nm (24 ft. lbs.). 5. Install the return tube (1) at the gear (3). Tighten the tube nut to 20 Nm (15 ft. lbs.). 6. Install the return hose (1) at the return tube (2). 7. Lower the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler > Page 1467 8. Install the pressure hose (3) at the pump pressure port (5). Tighten the tube nut to 32 Nm (24 ft. lbs.). 9. Install the pressure hose routing bracket bolt (2) to the upper mount (8). 10. All except 2.4L Engine with All-Wheel-Drive - Position the pressure hose routing clamp (2) at the exhaust manifold and install the mounting bolt (1). Tighten the bolt to 9 Nm (80 in. lbs.). 11. 2.4L Engine with All-Wheel-Drive - Position the pressure hose routing clamp (2) at the exhaust manifold and install the mounting bolt (1). Tighten the bolt to 9 Nm (80 in. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler > Page 1468 12. Fill and bleed the power steering system. 13. Check for leaks. 14. Install the engine appearance cover. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler > Page 1469 Power Steering Line/Hose: Service and Repair Return Hose Removal REMOVAL NOTE: Before proceeding, refer to STEERING WARNING. 1. Remove the engine appearance cover. 2. Remove the coolant recovery bottle. 3. Siphon as much fluid as possible from the power steering fluid reservoir. 4. Remove the power steering fluid reservoir. 5. Remove the windshield washer reservoir. 6. Remove the front fascia. 7. Remove the right headlamp. 8. Raise and support the vehicle. 9. Remove the return hose (1) at the return tube (2). 10. Remove the return hose routing clamp screw (2) securing the return hose (7) to the frame rail. 11. Lower the vehicle. 12. Remove the return hose routing clamp screw (1) securing the return hose (7) to the strut tower. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler > Page 1470 13. Remove the hose clamps (6) securing the return hose to the power steering reservoir and cooler. Slide the hose off the end of the cooler tube. 14. Remove the return hose from the vehicle. Installation INSTALLATION 1. Install the power steering return hose (7) into the engine compartment. 2. Install the return hose routing clamp screw (1) securing the return hose (7) to the strut tower. 3. Install the return hose onto the cooler tubes (5) and install the hose clamps (6). 4. Raise and support the vehicle. 5. Install the screw (2) securing the return hose to the frame rail. Tighten the screw to 19 Nm (14 ft. lbs.). 6. Install the return hose (1) at the return tube (2). 7. Lower the vehicle. 8. Install the right headlamp. 9. Install the front fascia. 10. Install the windshield washer reservoir. 11. Install the power steering fluid reservoir. 12. Install the coolant recovery bottle. 13. Fill and bleed the power steering system. 14. Check for leaks. 15. Install the engine appearance cover. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler > Page 1471 Power Steering Line/Hose: Service and Repair Hose-Supply Removal GAS ENGINE NOTE: Before proceeding, refer to STEERING WARNING. 1. Siphon as much fluid as possible from the power steering fluid reservoir. 2. Remove the clamp (2) securing the supply hose to the power steering pump (3) supply fitting, then remove the hose from the supply fitting. 3. Remove the hose clamp securing the supply hose (4) to the power steering fluid reservoir (5). Slide the hose off the end of the reservoir fitting and remove from vehicle. Installation Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler > Page 1472 GAS ENGINE 1. Slide hose clamps (2) onto both ends of the power steering fluid supply hose (1) far enough to clear the fittings on the reservoir and pump once the hose is installed. 2. Place the pump end of the supply hose (1) onto the pump (3) supply fitting. Expand the hose clamp (2) and slide it over the hose and pump supply fitting. Secure the clamp once it is past the bead formed into the fluid supply fitting. 3. Expand the hose clamp (4) at the fluid reservoir (5) and slide it over the hose and fitting. Secure the clamp once it is past the bead formed into the fluid reservoir fitting. 4. Perform the POWER STEERING PUMP BLEED PROCEDURE. 5. Check for leaks at all hose connections. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Brake Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1478 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Page 1479 Brake Fluid: Specifications BRAKE FLUID The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar(R) Brake Fluid DOT 3 Motor Vehicle or equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum-based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Page 1480 Brake Fluid: Testing and Inspection BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swelling indicates the presence of petroleum in the brake fluid. To test for contamination, put a small amount of drained brake fluid in clear glass jar. If the fluid separates into layers, there is mineral oil or other fluid contamination of the brake fluid. If the brake fluid is contaminated, drain and thoroughly flush the brake system. Replace all the rubber parts or components containing rubber coming into contact with the brake fluid including: the master cylinder and reservoir; proportioning valves (non-ABS); caliper seals; wheel cylinder seals; ABS hydraulic control unit; and all hydraulic fluid hoses. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Page 1481 Brake Fluid: Service and Repair BRAKE FLUID LEVEL CHECKING NOTE: Brake fluid level should be checked a minimum of twice a year. Master cylinder reservoirs (2) are marked, FULL and ADD, indicating the allowable brake fluid level range in the master cylinder fluid reservoir. CAUTION: Use only Mopar(R) Brake Fluid DOT 3 Motor Vehicle or equivalent from a tightly sealed container. Do not use petroleum-based fluid because seal damage in the brake system will result. NOTE: Although there is a range, the preferred level is FULL. 1. Remove the cap (1). 2. Adjust the brake fluid level to the FULL mark listed on the side of the master cylinder fluid reservoir (2) as necessary. Do not overfill the system. 3. Install the cap (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Clutch Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1486 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Technical Service Bulletins > Page 1487 Clutch Fluid: Specifications Clutch Fluid Type Mopar DOT 3, SAE J1703 should be used. If DOT 3, SAE J1703 brake fluid is not available, then DOT 4 is acceptable. Use only recommended brake fluids or equivalent. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Coolant: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1492 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Cooling System Fluid Capacity Engine Coolant .................................................................................................................................... ............................................... 7.2 Quarts (6.8 Liters) Note: Includes heater and coolant recovery bottled filled to MAX level. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1495 Coolant: Fluid Type Specifications Cooling System Fluid Type Mopar Antifreeze/Coolant 5 year/100,000 mile formula HOAT (Hybrid Organic Additive Technology) or equivalent. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Coolant Coolant: Description and Operation Coolant ENGINE COOLANT WARNING: Antifreeze is an ethylene glycol base coolant and is harmful if swallowed or inhaled. If swallowed, drink two glasses of water and induce vomiting. If inhaled, move to fresh air area, seek medical attention immediately. Do not store in open or unmarked containers. Wash skin and clothing thoroughly after coming in contact with ethylene glycol. Keep out of reach of children. Dispose of glycol base coolant properly, contact your dealer or government agency for location of collection center in your area. Do not open a cooling system when the engine is at operating temperature or hot under pressure, personal injury can result. Avoid radiator cooling fan when engine compartment related service is performed, personal injury can result. ETHYLENE-GLYCOL MIXTURES CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only Mopar(R) Antifreeze/Coolant, 5 year/100,000 Mile Formula (ethylene-glycol base coolant with corrosion inhibitors called HOAT, (Hybrid Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain a freeze point of -37° C (-35° F). The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle operating conditions. The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower than 44 percent, engine parts may be eroded by cavitation, and cooling system components may be severely damaged by corrosion. Maximum protection against freezing is provided with a 68% antifreeze concentration, which prevents freezing down to -67.7° C (-90° F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because the specific heat of antifreeze is lower than that of water. Use of 100 percent ethylene-glycol will cause formation of additive deposits in the system, as the corrosion inhibitive additives in ethylene-glycol require the presence of water to dissolve. The deposits act as insulation, causing temperatures to rise to as high as 149° C (300° F). This temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at 22° C (-8° F). PROPYLENE-GLYCOL MIXTURES It's overall effective temperature range is smaller than that of ethylene-glycol. The freeze point of 50/50 propylene-glycol and water is -32° C (-26° F). 5° C higher than ethylene-glycol's freeze point. The boiling point (protection against summer boil-over) of propylene-glycol is 125° C (257° F) at 96.5 kPa (14 psi), compared to 128° C (263° F) for ethylene-glycol. Use of propylene-glycol can result in boil-over or freeze-up on a cooling system designed for ethylene-glycol. Propylene glycol also has poorer heat transfer characteristics than ethylene glycol. This can increase cylinder head temperatures under certain conditions. Propylene-glycol/ethylene-glycol Mixtures can cause the destabilization of various corrosion inhibitors, causing damage to the various cooling system components. Also, once ethylene-glycol and propylene-glycol based coolants are mixed in the vehicle, conventional methods of determining freeze point will not be accurate. Both the refractive index and specific gravity differ between ethylene glycol and propylene glycol. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Coolant > Page 1498 Coolant: Description and Operation Description HOAT COOLANT WARNING: Antifreeze is an ethylene-glycol base coolant and is harmful if swallowed or inhaled. If swallowed, drink two glasses of water and induce vomiting. If inhaled, move to fresh air area. Seek medical attention immediately. Do not store in open or unmarked containers. Wash skin and clothing thoroughly after coming in contact with ethylene-glycol. Keep out of reach of children. Dispose of glycol base coolant properly, contact your dealer or government agency for location of collection center in your area. Do not open a cooling system when the engine is at operating temperature or hot under pressure, personal injury can result. Avoid radiator cooling fan when engine compartment related service is performed, personal injury can result. CAUTION: Use of Propylene-Glycol based coolants is not recommended, as they provide less freeze protection and less corrosion protection. The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/fin radiator can transfer the heat to the air. The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Mopar(R) Antifreeze/Coolant, 5 Year/160.00 km, (100,000 Mile) Formula (MS-9769), or the equivalent ethylene-glycol base coolant with organic corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% ethylene-glycol and 50% distilled water to obtain a freeze point of -37° C (-35° F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. CAUTION: Mopar(R) Antifreeze/Coolant, 5 Year/160.00 km (100,000) Mile Formula (MS-9769) may not be mixed with any other type of antifreeze. Mixing of coolants other than specified (non-HOAT or other HOAT), may result in engine damage that may not be covered under the new vehicle warranty, and decreased corrosion protection. COOLANT PERFORMANCE The required ethylene-glycol (antifreeze) and water mixture depends upon climate and vehicle operating conditions. The coolant performance of various mixtures follows: Pure Water - Water can absorb more heat than a mixture of water and ethylene-glycol. This is for purpose of heat transfer only. Water also freezes at a higher temperature and allows corrosion. 100 percent Ethylene-Glycol - The corrosion inhibiting additives in ethylene-glycol need the presence of water to dissolve. Without water, additives form deposits in system. These act as insulation causing temperature to rise to as high as 149° C (300° F). This temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at -22° C (-8° F). 50/50 Ethylene-Glycol and Water - Is the recommended mixture, it provides protection against freezing to -37° C (-34° F). The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower, engine parts may be eroded by cavitation. Maximum protection against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing down to -67.7° C (-90° F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because specific heat of antifreeze is lower than that of water. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. COOLANT SELECTION AND ADDITIVES The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only Mopar(R) Antifreeze/Coolant, 5 Year/160.000 km (100,000 Mile) Formula (glycol base coolant with corrosion inhibitors called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain a freeze point of -37° C (-35° F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. CAUTION: Do not use coolant additives that are claimed to improve engine cooling. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Coolant > Page 1499 Coolant: Description and Operation Operation OPERATION Coolant flows through the engine block absorbing the heat from the engine, then flows to the radiator where the cooling fins in the radiator transfers the heat from the coolant to the atmosphere. During cold weather the ethylene-glycol or propylene-glycol coolant prevents water present in the cooling system from freezing within temperatures indicated by mixture ratio of coolant to water. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Testing and Inspection > Coolant Concentration Testing Coolant: Testing and Inspection Coolant Concentration Testing COOLANT CONCENTRATION TESTING Coolant concentration should be checked when any additional coolant was added to system or after a coolant drain, flush and refill. The coolant mixture offers optimum engine cooling and protection against corrosion when mixed to a freeze point of -37° C (-34° F) to -46° C (-50° F). The use of a hydrometer or a refractometer can be used to test coolant concentration. A hydrometer will test the amount of glycol in a mixture by measuring the specific gravity of the mixture. The higher the concentration of ethylene glycol, the larger the number of balls that will float, and higher the freeze protection (up to a maximum of 60% by volume glycol). A refractometer Tool 8286 will test the amount of glycol in a coolant mixture by measuring the amount a beam of light bends as it passes through the fluid. Some coolant manufactures use other types of glycols into their coolant formulations. Propylene glycol is the most common new coolant. However, propylene glycol based coolants do not provide the same freezing protection and corrosion protection and is not recommended. CAUTION: Do not mix types of coolant corrosion protection will be severely reduced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Testing and Inspection > Coolant Concentration Testing > Page 1502 Coolant: Testing and Inspection Coolant Level Check COOLANT LEVEL CHECK NOTE: Do not remove pressure cap for routine coolant level inspections. The coolant recovery/reserve system provides a quick visual method for determining the coolant level without removing the radiator cap. Simply observe, with the engine idling and warmed up to normal operating temperature, that the level of the coolant in the recovery/reserve container is between the FULL HOT and ADD marks. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - A/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1507 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - CVT: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1512 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - M/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1517 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - Transfer Case: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1522 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - A/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1527 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - CVT: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1532 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - M/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1537 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Manual Transmission Fluid Capacity NV T355 .............................................................................................................................................. ................................................ 2.4-2.7 L (2.5-2.8 Qt) BG6 ..................................................................................................................................................... ............................................................. 2.0 L (2.1 Qt) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 1540 Fluid - M/T: Fluid Type Specifications Manual Transaxle Fluid Manual Fluid ........................................................................................................................................ ............................................ Mopar ATF+4 MS9602 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Service and Repair > BG6 Manual Transaxle Fluid - M/T: Service and Repair BG6 Manual Transaxle Fluid Level Checking FLUID LEVEL CHECKING The fluid required for this transaxle is Mopar(R) ATF+4 (Automatic Transmission Fluid). Use of improper or substitute fluids can cause shift problems and/or transaxle failure. 1. Insure the vehicle is level, remove the fill plug and add fluid until the fluid just starts to trickle out. Fluid Drain And Fill FLUID DRAIN AND FILL NOTE: The fluid required for this transaxle is Mopar(R) ATF+4 (Automatic Transmission Fluid). Use of improper or substitute fluids can cause shift problems and/or transaxle failure. 1. Raise vehicle on hoist. 2. Obtain suitable fluid collection container and place under transaxle. 3. Remove transaxle drain plug (2). Allow fluid to drain into container until empty. 4. Install the drain plug (1) with a new gasket and tighten to 39 Nm (29 ft. lbs.). 5. Remove transaxle fill plug (1). 6. Add the appropriate amount of transaxle fluid to the transaxle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Service and Repair > BG6 Manual Transaxle > Page 1543 Fluid - M/T: Service and Repair T355 Manual Transaxle STANDARD PROCEDURE - FLUID DRAIN AND FILL NOTE: All T355 Manual Transaxles require the use of ATF+4 (Automatic Transmission Fluid). The transaxle fill plug (1) is located on the left side of the transaxle differential area. The fluid level should be within 3/16 inch from the bottom of the transaxle fill hole (vehicle must be level when checking). The transaxle drain plug (2) is located on the lower right side of the transaxle differential housing. Tighten drain plug to 14 Nm (120 in. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - Differential: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1548 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - Transfer Case: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1553 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Engine Oil: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1558 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil and Oil Filter Capacity .......................................................................................................................................................... 4.5 Qt (4.26 Liters) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1561 Engine Oil: Fluid Type Specifications Engine Oil Type ................................................................................................................................... ............................................................... SAE 5W-20 Use API certified engine oil. Refer to engine oil filler cap for correct SAE grade meeting Daimler Chrysler Material Standard MS-6395. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1562 Engine Oil: Testing and Inspection ENGINE OIL LEVEL CHECK NOTE: The engine must be HOT when checking oil level. The best time to check engine oil level is after the engine is at operating temperature. Allow the engine to be shut off for at least 5 minutes before checking oil level. Checking the oil while the vehicle is on level ground will improve the accuracy of the oil level reading. Remove dipstick (1), and observe oil level. Add oil only when the level is at or below the SAFE mark. If the oil level is in the safe (2) range, do not add oil. CAUTION: Do not operate engine if the oil level is above the MAX mark on the dipstick. Excessive oil volume can cause oil aeration which can lead to engine failure due to loss of oil pressure or increase in oil temperature. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1563 Engine Oil: Service and Repair ENGINE OIL AND FILTER CHANGE WARNING: New or used engine oil can be irritating to the skin. Avoid prolonged or repeated skin contact with engine oil. Contaminants in used engine oil, caused by internal combustion, can be hazardous to your health. Thoroughly wash exposed skin with soap and water. Do not wash skin with gasoline, diesel fuel, thinner, or solvents, health problems can result. Do not pollute, dispose of used engine oil properly. Contact your dealer or government agency for location of collection center in your area. Change engine oil at mileage and time intervals described in the Maintenance Schedule. 1. Run engine until achieving normal operating temperature. 2. Position the vehicle on a level surface and turn engine off. 3. Remove oil fill cap. 4. Raise vehicle on hoist. 5. Place a suitable oil collecting container under oil pan drain plug (2). 6. Remove oil pan drain plug (2) or and allow oil to drain into collecting container. Inspect drain plug threads for stretching or other damage. Replace drain plug and gasket if damaged. 7. Remove oil filter (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1564 8. Install oil pan drain plug (2) and tighten drain plug to 28 Nm (20 ft. lbs.). 9. Install new oil filter (1). 10. Lower vehicle and fill crankcase with specified type and amount of engine oil. 11. Install oil fill cap. 12. Start engine and inspect for leaks. 13. Stop engine and inspect oil level. OIL FILTER SPECIFICATION All engines are equipped with a high quality full-flow, disposable type oil filter. Replace oil filter with a Mopar(R) or the equivalent. USED ENGINE OIL DISPOSAL Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to the WARNING listed above. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Power Steering Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1569 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 1570 Power Steering Fluid: Specifications Power Steering Fluid Type Mopar Power Steering Fluid +4 or Mopar Automatic Transmission Fluid. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 1571 Power Steering Fluid: Description and Operation DESCRIPTION The recommended fluid for the power steering system is Mopar(R) Power Steering fluid + 4 or Mopar(R) ATF+4 Automatic Transmission Fluid. Both fluids have the same material standard specifications (MS-9602). Mopar(R) ATF+4 (and Mopar(R) Power Steering fluid + 4), when new, is red in color. ATF+4 is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, ATF+4 will begin to look darker in color and may eventually become brown. THIS IS NORMAL. ATF+4 also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 1572 Power Steering Fluid: Testing and Inspection POWER STEERING FLUID LEVEL CHECKING WARNING: Fluid level should be checked with the engine OFF to prevent personal injury from moving parts and to assure an accurate fluid level reading. CAUTION: Mopar(R) Power Steering Fluid + 4 or Mopar(R) ATF+4 Automatic Transmission Fluid is to be used in the power steering system. Both fluids have the same material standard specifications (MS-9602). No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if another fluid is used. Do not overfill the system. NOTE: Although not required at specific intervals, the fluid level may be checked periodically. Check the fluid level anytime there is a system noise or fluid leak suspected. The power steering fluid level can be viewed through the side of the power steering fluid reservoir. Compare the fluid level to the markings on the side of the reservoir. When the fluid is at normal ambient temperature, approximately 21° C to 27° C (70° F to 80° F), the fluid level should read between the MAX. and MIN. markings. When the fluid is hot, fluid level is allowed to read up to the MAX. line. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 1573 Power Steering Fluid: Service and Repair POWER STEERING SYSTEM BLEEDING WARNING: The fluid level should be checked with engine off to prevent injury from moving components. CAUTION: Mopar(R) Power Steering Fluid + 4 or Mopar(R) ATF+4 Automatic Transmission Fluid is to be used in the power steering system. Both Fluids have the same material standard specifications (MS-9602). No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if another fluid is used. Do not overfill the system. CAUTION: If the air is not purged from the power steering system correctly, pump failure could result. NOTE: Be sure the vacuum tool used in the following procedure is clean and free of any fluids. 1. Check the fluid level. As measured on the side of the reservoir, the level should indicate between MAX and MIN when the fluid is at normal ambient temperature. Adjust the fluid level as necessary. 2. Tightly insert Power Steering Cap Adapter (4), Special Tool 9688, into the mouth of the reservoir (3). CAUTION: Failure to use a vacuum pump reservoir (1) may allow power steering fluid to be sucked into the hand vacuum pump. 3. Attach Hand Vacuum Pump (2), Special Tool C-4207 or equivalent, with reservoir (1) attached, to the Power Steering Cap Adapter (4). CAUTION: Do not run the engine while vacuum is applied to the power steering system. Damage to the power steering pump can occur. NOTE: When performing the following step make sure the vacuum level is maintained during the entire time period. 4. Using Hand Vacuum Pump (2), apply 68-85 kPa (20-25 in. Hg) of vacuum to the system for a minimum of three minutes. 5. Slowly release the vacuum and remove the special tools. 6. Adjust the fluid level as necessary. Refer to STEP 1. 7. Repeat STEP 1 through STEP 6 until the fluid no longer drops when vacuum is applied. 8. Start the engine and cycle the steering wheel lock-to-lock three times. NOTE: Do not hold the steering wheel at the stops. 9. Stop the engine and check for leaks at all connections. 10. Check for any signs of air in the reservoir and check the fluid level. If air is present, repeat the procedure as necessary. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications Refrigerant: Specifications Refrigerant Charge Capacity Single Unit ........................................................................................................................................... ..................................................... 0.51kg (1.125 lbs) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Description and Operation > Description Refrigerant: Description and Operation Description DESCRIPTION The refrigerant used in this air conditioning system is a Hydro Fluoro Carbon (HFC), type R-134a. Unlike R-12, which is a Chloro Fluoro Carbon (CFC), R-134a refrigerant does not contain ozone-depleting chlorine. R-134a refrigerant is a non-toxic, non-flammable, clear, and colorless liquefied gas. Even though R-134a does not contain chlorine, it must be reclaimed and recycled just like CFC-type refrigerants. This is because R-134a is a greenhouse gas and can contribute to global warming. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Description and Operation > Description > Page 1579 Refrigerant: Description and Operation Operation OPERATION R-134a refrigerant is not compatible with R-12 refrigerant in an A/C system. Even a small amount of R-12 refrigerant added to an R-134a refrigerant system will cause A/C compressor failure, refrigerant oil sludge or poor A/C system performance. In addition, the polyalkylene glycol (PAG) synthetic refrigerant oils used in an R-134a refrigerant system are not compatible with the mineral-based refrigerant oils used in an R-12 refrigerant system. R-134a refrigerant system service ports, service tool couplers and refrigerant dispensing bottles have all been designed with unique fittings to ensure that an R-134a refrigerant system is not accidentally contaminated with the wrong refrigerant (R-12). There are also labels posted in the engine compartment of the vehicle and on the A/C compressor to identify that the A/C system is equipped with R-134a refrigerant. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Description and Operation > Page 1580 Refrigerant: Testing and Inspection REFRIGERANT SYSTEM LEAKS WARNING: R-134a service equipment or vehicle A/C system should not be pressure tested or leak tested with compressed air. Mixture of air and R-134a can be combustible at elevated pressures. These mixtures are potentially dangerous and may result in fire or explosion causing property damage, personal injury or death. Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Use only approved service equipment meeting SAE requirements to discharge an R-134a system. If accidental system discharge occurs, ventilate work area before resuming service. NOTE: If the A/C refrigerant system charge is empty or low, a leak in the A/C system is likely. Visually inspect all A/C lines, fittings and components for an oily residue. Oil residue can be an indicator of an A/C system leak location. NOTE: The only way to correctly determine if the refrigerant system is fully charged with R-134a is to completely evacuate and recharge the A/C system. Connect a suitable manifold gauge set and determine if the static A/C system pressure is above or below 345 kPa (50 psi). If less than 345 kPa (50 psi) , proceed to SYSTEM EMPTY. If greater than 345 kPa (50 psi), go to SYSTEM LOW. SYSTEM EMPTY 1. Evacuate the refrigerant system to the lowest degree of vacuum possible (approximately -88 kPa (-26 in. Hg) or greater vacuum). Determine if the system holds a vacuum for 15 minutes. If vacuum is held, a leak is probably not present. If system will not maintain vacuum level, proceed to STEP 2. 2. Prepare and dispense 0.284 kilograms (10 ounces) of R-134a refrigerant into the evacuated refrigerant system and proceed to STEP 1 of the System Low procedure. SYSTEM LOW 3. Position the vehicle in a wind-free work area. This will aid in detecting small leaks. 4. Operate the heating-A/C system with the engine at idle under the following conditions for at least 5 minutes. - Doors or windows open - Transaxle in Park or Neutral with the parking brake set (depending on application) - A/C-heater controls set to outside air, full cool, panel mode, high blower and with A/C compressor engaged CAUTION: A leak detector only designed for R-12 refrigerant will not detect leaks in an R-134a refrigerant system. 5. Shut the vehicle Off and wait 2-7 minutes. Then use an electronic leak detector that is designed to detect R-134a refrigerant and search for leaks. Fittings, lines or components that appear to be oily usually indicate a refrigerant leak. To inspect the A/C evaporator for leaks, insert the leak detector probe into the drain tube opening or an air outlet. A dye for R-134a is available to aid in leak detection. Use only DaimlerChrysler approved refrigerant dye. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant System Recovery Refrigerant: Service and Repair Refrigerant System Recovery REFRIGERANT SYSTEM RECOVERY WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions may result in serious or fatal injury. An R-134a refrigerant recovery/recycling/charging station (1) that meets SAE standard J2210 must be used to recover the refrigerant from the R-134a refrigerant system. Refer to the operating instructions supplied by the equipment manufacturer for the proper care and use of this equipment. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant System Recovery > Page 1583 Refrigerant: Service and Repair Refrigerant System Evacuate REFRIGERANT SYSTEM EVACUATE CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system. Failure to follow this caution will result in serious A/C compressor damage. NOTE: Special effort must be used to prevent moisture from entering the A/C system oil. Moisture in the oil is very difficult to remove and will cause a reliability problem with the A/C compressor. If an A/C compressor designed to use R-134a refrigerant is left open to the atmosphere for an extended period of time. It is recommended that the refrigerant oil be drained and replaced with new oil or a new A/C compressor be used. This will eliminate the possibility of contaminating the refrigerant system. If the refrigerant system has been open to the atmosphere, it must be evacuated before the system can be filled. Moisture and air mixed with the refrigerant will raise the compressor head pressure above acceptable operating levels. This will reduce the performance of the A/C system and damage the A/C compressor. Moisture will boil at near room temperature when exposed to vacuum. To evacuate the refrigerant system: NOTE: When connecting the service equipment coupling to the line fitting, verify that the valve of the coupling is fully closed. This will reduce the amount of effort required to make the connection. 1. Recover the refrigerant system. 2. With the engine OFF, connect a suitable charging station, refrigerant recovery machine or a manifold gauge set with vacuum pump and refrigerant recovery equipment. Do not operate the engine with a vacuum on the A/C system. 3. Open the suction and discharge valves and start the vacuum pump. The vacuum pump should run a minimum of 45 minutes prior to charge to eliminate all moisture in system. When the suction gauge reads to the lowest degree of vacuum possible (approximately -88 kPa (- 26 in. Hg) or greater) for 30 minutes, close all valves and turn off vacuum pump. If the system fails to reach specified vacuum, the refrigerant system likely has a leak that must be corrected. If the refrigerant system maintains specified vacuum for at least 30 minutes, start the vacuum pump, open the suction and discharge valves. Then allow the system to evacuate an additional 10 minutes. 4. Close all valves. Turn off and disconnect the vacuum pump. 5. Charge the refrigerant system. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant System Recovery > Page 1584 Refrigerant: Service and Repair Refrigerant System Charge REFRIGERANT SYSTEM CHARGE WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death. NOTE: The Underhood HVAC Specification Label contains the refrigerant fill specification of the vehicle being serviced. After all refrigerant system leaks have been repaired and the refrigerant system has been evacuated, a refrigerant charge can be injected into the system. An R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 must be used to charge the refrigerant system with R-134a refrigerant. Refer to the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment. CHARGING PROCEDURE CAUTION: A small amount of refrigerant oil is removed from the A/C system each time the refrigerant system is recovered and evacuated. Before charging the A/C system, you MUST replenish any oil lost during the recovery process. 1. Evacuate the refrigerant system. 2. A manifold gauge set and an R-134a refrigerant recovery/recycling/charging station that meets SAE standard J2210 should be connected to the refrigerant system. 3. Measure the proper amount of refrigerant and heat it to 52° C (125° F) with the charging station. See the operating instructions supplied by the equipment manufacturer for proper use of this equipment. 4. Open both the suction and discharge valves, then open the charge valve to allow the heated refrigerant to flow into the system. 5. When the transfer of refrigerant has stopped, close both the suction and discharge valves. 6. If all of the refrigerant charge did not transfer from the dispensing device, open all of the windows in the vehicle and set the heating-A/C system controls so that the A/C compressor is operating and the blower motor is running at its lowest speed setting. Run the engine at a steady high idle (about 1400 rpm). 7. Open the low-side valve to allow the remaining refrigerant to transfer to the refrigerant system. WARNING: Take care not to open the discharge (high pressure) valve at this time. Failure to follow this warning could result in possible personal injury or death. 8. Disconnect the charging station and manifold gauge set from the refrigerant system service ports. 9. Reinstall the caps onto the refrigerant system service ports. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Page 1585 Refrigerant: Tools and Equipment REFRIGERANT SYSTEM SERVICE EQUIPMENT WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death. WARNING: Eye protection must be worn when servicing an air conditioning refrigerant system. Turn off (rotate clockwise) all valves on the equipment being used, before connecting to or disconnecting from the refrigerant system. Failure to observe these warnings may result in personal injury or death. When servicing the A/C system, an R-134a refrigerant recovery/recycling/charging station that meets SAE standard J2210 must be used (1). Contact an automotive service equipment supplier for refrigerant recovery/recycling/charging equipment. Refer to the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment. A manifold gauge set (1) may be needed with some recovery/recycling/charging equipment. The manifold gauge set should have manual shut-off valves (2 and 6), or automatic back-flow valves located at the service port connector end of the manifold gauge set hoses (4 and 5). This will prevent refrigerant Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Page 1586 from being released into the atmosphere. MANIFOLD GAUGE SET CONNECTIONS CAUTION: Do not use an R-12 manifold gauge set on an R-134a system. The refrigerants are not compatible and system damage will result. - LOW PRESSURE GAUGE HOSE - The low pressure hose (Blue with Black stripe) attaches to the low side service port. This port is located on the A/C liquid line near the right front strut tower. - HIGH PRESSURE GAUGE HOSE - The high pressure hose (Red with Black stripe) attaches to the high side service port. This port is located on the A/C discharge line near the A/C condenser. - RECOVERY/RECYCLING/EVACUATION/CHARGING HOSE - The center manifold hose (Yellow, or White, with Black stripe) is used to recover, evacuate, and charge the refrigerant system. When the low or high pressure valves on the manifold gauge set are opened, the refrigerant in the system will escape through this hose. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Description and Operation > Description Refrigerant Oil: Description and Operation Description DESCRIPTION The refrigerant oil used in R-134a refrigerant systems is a synthetic-based, polyalkylene glycol (PAG), wax-free lubricant. Mineral-based R-12 refrigerant oils are not compatible with PAG oils and should never be introduced to an R-134a refrigerant system. There are different PAG oils available and each contain a different additive package. Always use only the type of refrigerant oil recommended for the A/C compressor in the vehicle. CAUTION: Be certain to adjust the refrigerant system oil level when replacing an A/C compressor. Failure to properly adjust the refrigerant oil level can prevent the A/C system from operating as designed and can cause serious A/C compressor damage. The Denso 5SE12C A/C compressor used in this vehicle is designed to use ND-8 PAG refrigerant oil. Use only this type of refrigerant oil in the refrigerant system. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Description and Operation > Description > Page 1592 Refrigerant Oil: Description and Operation Operation OPERATION After performing any refrigerant recovery or recycling operation, always replenish the refrigerant system with the same amount of the recommended refrigerant oil as was removed. Too little refrigerant oil can cause A/C compressor damage, and too much can reduce A/C system performance. PAG refrigerant oil is more hygroscopic than mineral oil, and will absorb any moisture it comes into contact with, even moisture in the air. The PAG oil container should always be kept tightly capped until it is ready to be used. After use, recap the oil container immediately to prevent moisture contamination. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Description and Operation > Page 1593 Refrigerant Oil: Service and Repair REFRIGERANT OIL LEVEL When an A/C system is assembled at the factory, all components except the A/C compressor are refrigerant oil free. After the refrigerant system has been charged and operated, the refrigerant oil in the A/C compressor is dispersed throughout the refrigerant system. The A/C accumulator, A/C evaporator, A/C condenser and the A/C compressor will each retain a significant amount of the needed refrigerant oil. It is important to have the correct amount of refrigerant oil in the A/C system. This ensures proper lubrication of the A/C compressor. Too little oil will result in damage to the A/C compressor, while too much oil will reduce the cooling capacity of the A/C system and consequently result in higher discharge air temperatures. CAUTION: ND-8 PAG refrigerant oil is used in the Denso 5SE12C A/C compressor. Only refrigerant oil of the same type should be used to service this R-134a A/C system. Do not use any other refrigerant oil. The refrigerant oil container should be kept tightly capped until it is ready for use and then tightly capped after use to prevent contamination from moisture and dirt. Refrigerant oil will quickly absorb any moisture it comes in contact with, therefore, special effort must be used to keep all R-134a system components moisture-free. Moisture in the refrigerant oil is very difficult to remove and will cause a reliability problem with the A/C compressor. NOTE: Most reclaim/recycling equipment will measure the amount of refrigerant oil being removed during the recovery process. This amount of refrigerant oil should always be added back into the refrigerant system. It will not be necessary to check the oil level within the A/C refrigerant system or to add oil, unless there has been an oil loss. A refrigerant oil loss may occur due to component replacement or a rupture or leak from a refrigerant line, connector fitting, component or component seal. If a leak does occurs, add 30 milliliters (1 fluid ounce) of the recommended refrigerant oil to the refrigerant system after the repair has been made. Refrigerant oil loss will be evident at the leak point by the presence of a wet, shiny surface around the leak. Refrigerant oil must be added when an A/C accumulator, A/C evaporator or A/C condenser is replaced. Refer to the Refrigerant Oil Capacities chart. The refrigerant oil level in a new A/C compressor must first be adjusted prior to compressor installation. Refer to the following COMPRESSOR OIL DRAIN PROCEDURE. COMPRESSOR OIL DRAIN PROCEDURE CAUTION: Be certain to adjust the refrigerant system oil level when replacing an A/C compressor. The refrigerant oil in the Denso 5SE12C A/C compressor can only be drained using the procedure described below. Failure to properly drain the refrigerant oil from the A/C compressor can prevent the A/C system from operating as designed and cause serious compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be removed from the new A/C compressor (example: new compressor and accumulator requires 80 ml. (2.7 oz.) of oil to be added to the system. 120 ml. (4.1 oz.) of oil is in new compressor. 120 ml. (4.1 oz.) minus 80 ml. (2.7 oz.) equals 40 ml. (1.4 oz.) oil to be drained from new compressor). The Denso 5SE12C A/C compressor is filled with 120 milliliters (4.1 oz.) from the factory. When only the A/C compressor is being replaced, 70 milliliters (2.4 oz.) of refrigerant oil must first be drained from the new compressor prior to installation. Use the following procedure to drain and measure refrigerant oil from the Denso 5SE12C A/C compressor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Description and Operation > Page 1594 1. Place the new A/C compressor (1) on a workbench, 2. Position the A/C compressor so that the refrigerant oil can drain out of the suction port (2) into a suitable clean measured container. Hold the A/C compressor in this position until no more oil comes out of the compressor port. 3. Reposition the A/C compressor (1) so that the pulley (2) is facing upward and slowly rotate the compressor pulley clockwise one full turn. 4. Repeat steps 2 and 3 at least seven times or until 70 milliliters (2.4 oz.) of refrigerant oil is drained from the new A/C compressor. CAUTION: Failure to properly adjust the refrigerant oil level prior to installation of a new compressor can prevent the A/C system from operating as designed and cause serious compressor damage. 5. Install the new A/C compressor onto the engine. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding Brake Bleeding: Service and Repair Master Cylinder Bleeding MASTER CYLINDER BLEEDING NOTE: On vehicles without ABS this procedure is designed to be performed with the proportioning valves installed in the master cylinder. 1. Clamp the master cylinder in a vise with soft-jaw caps. 2. Master Cylinder without ABS - Attach the special tools for bleeding the master cylinder in the following fashion: a. Thread Bleeder Tube Adapter (1), Special Tool 8822-1, into the primary outlet port of the master cylinder without a proportioning valve. Tighten Adapter to 17 Nm (150 in. lbs.). b. Thread Bleeder Tube Adapter (2), Special Tool 8822-2, into the secondary outlet port of the master cylinder without a proportioning valve. Tighten Adapter to 17 Nm (150 in. lbs.). c. Thread Bleeder Tube Adapter (4), Special Tool 8822-1, into the proportioning valve in the lower secondary outlet port of the master cylinder. Tighten Adapter to 17 Nm (150 in. lbs.). d. Thread Bleeder Tube Adapter (5), Special Tool 8822-2, into the proportioning valve in the lower primary outlet port of the master cylinder. Tighten Adapter to 17 Nm (150 in. lbs.). e. Thread a Bleeder Tube (6), Special Tool 8358-1, into each Adapter. Tighten tube nuts to 17 Nm (150 in. lbs.). f. Install Bleeder Tubes Adapter (3), Special Tool 9705, in place of the fill cap as shown. g. Flex and place the open ends of the Bleeder Tubes into open hose tips on Adapter 9705. Be sure Bleeder Tubes are inserted into Adapter 9705 far enough not to come loose during bleed procedure. 3. Master Cylinder with ABS - Attach the special tools for bleeding the master cylinder in the following fashion: a. Thread Bleeder Tube Adapters (3), Special Tool 8822-2, into the primary and secondary outlet ports of the master cylinder. Tighten Adapters to 17 Nm (150 in. lbs.). b. Thread a Bleeder Tube (2), Special Tool 8358-1, into each Adapter. Tighten tube nuts to 17 Nm (150 in. lbs.). c. Flex each Bleeder Tube and place the open ends into the neck of the master cylinder reservoir. Position the open ends of the tubes into the reservoir so their outlets are below the surface of the brake fluid in the reservoir when filled. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 1599 NOTE: Make sure the ends of the Bleeder Tubes stay below the surface of the brake fluid in the reservoir at all times during the bleeding procedure. 4. Fill the brake fluid reservoir with fresh Mopar(R) Brake Fluid DOT 3 Motor Vehicle, or equivalent. 5. Using an appropriately sized wooden dowel as a pushrod, slowly press the pistons inward discharging brake fluid through the Bleeder Tubes, then release the pressure, allowing the pistons to return to the released position. Repeat this several times until all air bubbles are expelled from the master cylinder bore and Bleeder Tubes. 6. Remove the Bleeder Tubes and Adapters from the master cylinder and plug the master cylinder outlet ports. 7. Install the fill cap on the reservoir. 8. Remove the master cylinder from the vise. 9. Install the master cylinder on the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 1600 Brake Bleeding: Service and Repair Base Brake Bleeding BASE BRAKE BLEEDING NOTE: For bleeding the ABS hydraulic system, refer to Antilock Brake System Bleeding in the Antilock Brake System. CAUTION: Before removing the master cylinder cap, wipe it clean to prevent dirt and other foreign matter from dropping into the master cylinder reservoir. CAUTION: Use only Mopar(R) brake fluid or an equivalent from a fresh, tightly sealed container. Brake fluid must conform to DOT 3 specifications. NOTE: For bleeding of the Antilock Brake System, Refer to BRAKES - ABS STANDARD PROCEDURE. Do not pump the brake pedal at any time while having a bleeder screw open during the bleeding process. This will only increase the amount of air in the system and make additional bleeding necessary. Do not allow the master cylinder reservoir to run out of brake fluid while bleeding the system. An empty reservoir will allow additional air into the brake system. Check the fluid level frequently and add fluid as needed. The following wheel circuit sequence for bleeding the brake hydraulic system should be used to ensure adequate removal of all trapped air from the hydraulic system. - Left rear wheel - Right front wheel - Right rear wheel - Left front wheel MANUAL BLEEDING NOTE: To bleed the brakes manually, the aid of a helper will be required. 1. Attach a clear plastic hose (1) to the bleeder screw and feed the hose into a clear jar (2) containing enough fresh brake fluid to submerge the end of the hose. 2. Have a helper pump the brake pedal three or four times and hold it in the down position. 3. With the pedal in the down position, open the bleeder screw at least one full turn. 4. Once the brake pedal has dropped, close the bleeder screw. After the bleeder screw is closed, release the brake pedal. 5. Repeat the above steps until all trapped air is removed from that wheel circuit (usually four or five times). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 1601 6. Bleed the remaining wheel circuits in the same manner until all air is removed from the brake system. Monitor the fluid level in the master cylinder reservoir (2) to make sure it does not go dry. 7. Check and adjust brake fluid level to the FULL mark. 8. Check the brake pedal travel. If pedal travel is excessive or has not been improved, some air may still be trapped in the system. Re-bleed the brakes as necessary. 9. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct. PRESSURE BLEEDING NOTE: Follow pressure bleeder manufacturer's instructions for use of pressure bleeding equipment. 1. Attach Master Cylinder Cap (2), Special Tool 6921, in place of the filler cap on the master cylinder reservoir (3). 2. Attach Bleeder Tank (1), Special Tool C-3496-B, or an equivalent, to the Master Cylinder Cap 6921. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 1602 3. Attach a clear plastic hose (1) to the bleeder screw and feed the hose into a clear jar (2) containing enough fresh brake fluid to submerge the end of the hose. 4. Open the bleeder screw at least one full turn or more to obtain a steady stream of brake fluid. 5. After approximately 120-240 ml (4-8 ounces) of fluid have been bled through the brake circuit and an air-free flow is maintained in the clear plastic hose and jar, close the bleeder screw. 6. Repeat this procedure at all the remaining bleeder screws. 7. Check and adjust brake fluid level to the FULL mark on the reservoir (2). 8. Check the brake pedal travel. If pedal travel is excessive or has not been improved, some air may still be trapped in the system. Re-bleed the brakes as necessary. 9. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 1603 Brake Bleeding: Service and Repair Antilock Brake System Bleeding ANTILOCK BRAKE SYSTEM BLEEDING The base brake's hydraulic system must be bled anytime air enters the hydraulic system. The ABS must always be bled anytime it is suspected that the HCU has ingested air. Brake systems with ABS must be bled as two independent braking systems. The non-ABS portion of the brake system with ABS is to be bled the same as any non-ABS system. The ABS portion of the brake system must be bled separately. Use the following procedure to properly bleed the brake hydraulic system including the ABS. NOTE: During the brake bleeding procedure, be sure the brake fluid level remains close to the FULL level in the master cylinder fluid reservoir. Check the fluid level periodically during the bleeding procedure and add Mopar(R) DOT 3 brake fluid as required. BLEEDING When bleeding the ABS system, the following bleeding sequence must be followed to insure complete and adequate bleeding. 1. Make sure all hydraulic fluid lines are installed and properly torqued. 2. Connect the scan tool to the diagnostics connector. The diagnostic connector is located under the lower steering column cover to the left of the steering column. 3. Using the scan tool, check to make sure the ABM does not have any fault codes stored. If it does, clear them. WARNING: When bleeding the brake system wear safety glasses. A clear bleed tube (1) must be attached to the bleeder screws and submerged in a clear container filled part way with clean brake fluid (2). Direct the flow of brake fluid away from yourself and the painted surfaces of the vehicle. Brake fluid at high pressure may come out of the bleeder screws when opened. NOTE: Pressure bleeding is recommended to bleed the base brake system to ensure all air is removed from system. Manual bleeding may also be used, but additional time is needed to remove all air from system. 4. Bleed the base brake system. 5. Using the scan tool, select ECU VIEW, followed by ABS MISCELLANEOUS FUNCTIONS to access bleeding. Follow the instructions displayed. When finished, disconnect the scan tool and proceed. 6. Bleed the base brake system a second time. Check brake fluid level in the reservoir periodically to prevent emptying, causing air to enter the hydraulic system. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 1604 7. Fill the master cylinder fluid reservoir (1) to the FULL level. 8. Test drive the vehicle to be sure the brakes are operating correctly and that the brake pedal does not feel spongy. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > Customer Interest for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems - Intermittent Component Operation Fuse: Customer Interest Electrical Systems - Intermittent Component Operation NUMBER:08-016-06 REV. A GROUP: Electrical DATE: July 18, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-016-06, DATED MARCH 22, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF A VEHICLE BODY STYLE. SUBJECT: Intermittent Operation Of Electrical Components Due To Ignition Off Draw (IOD) Fuse Not Being Fully Seated MODELS: 2007 (PM) Caliber **2007 (MK-49) Compass** 2006 - 2007 (DHIDRID1) Ram Truck 2006 - 2007 (PT) Chrysler PT Cruiser DISCUSSION: The Ignition Off Draw (IOD) fuse is used to prevent battery discharge during shipping and long term storage of the vehicles. The IOD fuse is located in the Total Integrated Power Module (TI PM). If the fuse is not completely inserted partial contact of the fuse terminals could occur. When the vehicle is prepped for customer delivery, ensure that the fuse is fully engaged (Fig. 1). The IOD fuse must also be fully released to prevent battery drain from occurring when the vehicle is stored. When the IOD fuse holder is depressed into the carrier, an initial distinct detent will be felt to overcome the "pre-hold position". You must then continue to push straight down on the IOD pre-holder until no further downward movement is encountered. NOTE: If the fuse is not pushed down symmetrically, two detents MAY be felt as each side snaps past the pre-hold position. Push down until no further downward movement is encountered. On 2006 and 2007 PT and PM vehicles the circuits fed by the IOD fuse are: Radio, Security module & siren (BUX), Wireless Control Module (RKE & SKREEM), Hands Free Module, Satellite Radio, Power Mirrors, Clock, Memory Seat, Amplifier, CCN wake-up with ignition off and Homelink. On 2006 and 2007 DR, DH or D1 vehicles the circuits fed by the IOD fuse are: Radio, EVIC, Wireless Control Module (RKE & SKREEM), Hands Free Module, Satellite Radio, Video Screen, CCN wake-up with ignition off, Underhood Lamp, CCN Interior Lighting Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > Customer Interest for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems - Intermittent Component Operation > Page 1614 POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems - Intermittent Component Operation Fuse: All Technical Service Bulletins Electrical Systems - Intermittent Component Operation NUMBER:08-016-06 REV. A GROUP: Electrical DATE: July 18, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-016-06, DATED MARCH 22, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF A VEHICLE BODY STYLE. SUBJECT: Intermittent Operation Of Electrical Components Due To Ignition Off Draw (IOD) Fuse Not Being Fully Seated MODELS: 2007 (PM) Caliber **2007 (MK-49) Compass** 2006 - 2007 (DHIDRID1) Ram Truck 2006 - 2007 (PT) Chrysler PT Cruiser DISCUSSION: The Ignition Off Draw (IOD) fuse is used to prevent battery discharge during shipping and long term storage of the vehicles. The IOD fuse is located in the Total Integrated Power Module (TI PM). If the fuse is not completely inserted partial contact of the fuse terminals could occur. When the vehicle is prepped for customer delivery, ensure that the fuse is fully engaged (Fig. 1). The IOD fuse must also be fully released to prevent battery drain from occurring when the vehicle is stored. When the IOD fuse holder is depressed into the carrier, an initial distinct detent will be felt to overcome the "pre-hold position". You must then continue to push straight down on the IOD pre-holder until no further downward movement is encountered. NOTE: If the fuse is not pushed down symmetrically, two detents MAY be felt as each side snaps past the pre-hold position. Push down until no further downward movement is encountered. On 2006 and 2007 PT and PM vehicles the circuits fed by the IOD fuse are: Radio, Security module & siren (BUX), Wireless Control Module (RKE & SKREEM), Hands Free Module, Satellite Radio, Power Mirrors, Clock, Memory Seat, Amplifier, CCN wake-up with ignition off and Homelink. On 2006 and 2007 DR, DH or D1 vehicles the circuits fed by the IOD fuse are: Radio, EVIC, Wireless Control Module (RKE & SKREEM), Hands Free Module, Satellite Radio, Video Screen, CCN wake-up with ignition off, Underhood Lamp, CCN Interior Lighting Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems - Intermittent Component Operation > Page 1620 POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > Page 1621 Fuse: Locations Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > Page 1622 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > Page 1623 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > Page 1624 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > Page 1625 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: Provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1628 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1629 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1630 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1631 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1632 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1633 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1634 5. Release the Secondary Terminal Lock, if required (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1635 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1636 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1637 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1638 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1639 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1640 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1641 Fuse: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1642 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1643 STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1644 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Page 1645 Fuse: Application and ID Totally Integrated Power Module Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Page 1646 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations Fuse Block: Locations Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Page 1650 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Page 1651 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Page 1652 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Page 1653 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: Provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1656 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1657 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1658 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1659 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1660 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1661 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1662 5. Release the Secondary Terminal Lock, if required (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1663 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1664 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1665 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1666 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1667 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1668 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1669 Fuse Block: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1670 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1671 STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1672 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Page 1673 Fuse Block: Application and ID Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Page 1674 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Page 1675 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Page 1676 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Page 1677 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Description and Operation > Description Fuse Block: Description and Operation Description DESCRIPTION An electrical Fuse Block is located in the left front bumper fascia. It serves to simplify and centralize numerous electrical components, as well as to distribute electrical current to many of the accessory systems in the vehicle. There are two clips that retain the fuse block cover to the fuse block. The cover can be removed to service the fuses and relays by depressing the clips and lifting off the cover. If fuse block wire terminal or insulator service is required the complete fuse block assembly must be removed. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Description and Operation > Description > Page 1680 Fuse Block: Description and Operation Operation OPERATION The fuse block houses relays and blade-type fuses. The fuses, relays and fuse block unit are available for service replacement. Refer to Wiring Diagrams for complete circuit diagrams. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Removal Fuse Block: Service and Repair Removal REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the front bumper fascia. 3. Depress mounting clips and lift the fuse block off the bracket. 4. Remove the wire harness and fuse block. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Removal > Page 1683 Fuse Block: Service and Repair Installation INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Install the new wire harness and fuse block into the vehicle. 2. Position the fuse block onto the mounting bracket and push down until the mounting clips are fully seated. 3. Install the front bumper fascia. 4. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations Relay Box: Locations Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1687 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1688 Relay Box: Application and ID Fuse/Relay Block Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Service and Repair Maintenance Required Lamp/Indicator: Service and Repair DaimlerChrysler provides no information regarding a Maintenance Required Lamp/Indicator for this vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair DaimlerChrysler provides no information regarding an Oil Change Reminder Lamp for this vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front Tire Pressure Monitor Receiver / Transponder: Locations Transponder-Tire Pressure-Left Front Component ID: 361 Component : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Connector: Name : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Color : YELLOW # of pins : 6 Qualifier : (TIRE PRESSURE MONITOR) Pin Description Circuit 1 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 GROUND Z904 20BK/OR 4 GROUND Z904 20BK/OR 5-6-- Component Location - 13 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 1702 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 1703 Tire Pressure Monitor Receiver / Transponder: Locations Transponder-Tire Pressure-Left Rear Component ID: 362 Component : TRANSPONDER-TIRE PRESSURE-LEFT REAR Connector: Name : TRANSPONDER-TIRE PRESSURE-LEFT REAR Color : BLACK # of pins : 6 Qualifier : (TIRE PRESSURE MONITOR) Pin Description Circuit 1 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 GROUND Z904 20BK/OR 4-5-6-- Component Location - 58 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 1704 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 1705 Tire Pressure Monitor Receiver / Transponder: Locations Transponder-Tire Pressure-Right Rear Component ID: 363 Component : TRANSPONDER-TIRE PRESSURE-RIGHT REAR Connector: Name : TRANSPONDER-TIRE PRESSURE-RIGHT REAR Color : BLACK # of pins : 6 Qualifier : (TIRE PRESSURE MONITOR) Pin Description Circuit 1 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 GROUND Z965 20BK/GY 4-5-6 GROUND Z965 20BK/GY Component Location - 59 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 1706 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front Tire Pressure Monitor Receiver / Transponder: Diagrams Transponder-Tire Pressure-Left Front Component ID: 361 Component : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Connector: Name : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Color : YELLOW # of pins : 6 Qualifier : (TIRE PRESSURE MONITOR) Pin Description Circuit 1 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 GROUND Z904 20BK/OR 4 GROUND Z904 20BK/OR 5-6-- Component Location - 13 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 1709 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 1710 Tire Pressure Monitor Receiver / Transponder: Diagrams Transponder-Tire Pressure-Left Rear Component ID: 362 Component : TRANSPONDER-TIRE PRESSURE-LEFT REAR Connector: Name : TRANSPONDER-TIRE PRESSURE-LEFT REAR Color : BLACK # of pins : 6 Qualifier : (TIRE PRESSURE MONITOR) Pin Description Circuit 1 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 GROUND Z904 20BK/OR 4-5-6-- Component Location - 58 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 1711 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 1712 Tire Pressure Monitor Receiver / Transponder: Diagrams Transponder-Tire Pressure-Right Rear Component ID: 363 Component : TRANSPONDER-TIRE PRESSURE-RIGHT REAR Connector: Name : TRANSPONDER-TIRE PRESSURE-RIGHT REAR Color : BLACK # of pins : 6 Qualifier : (TIRE PRESSURE MONITOR) Pin Description Circuit 1 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 GROUND Z965 20BK/GY 4-5-6 GROUND Z965 20BK/GY Component Location - 59 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 1713 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Description Tire Pressure Monitor Receiver / Transponder: Description and Operation Description DESCRIPTION A transponder, sometimes referred to as a trigger module, is located in three of the four wheel wells (behind the wheelhouse splash shields) of a vehicle equipped with Premium TPM. These transponders are used to provide the Wireless Control Module (WCM), commonly referred to as the Sentry Key Remote Entry Module (SKREEM), with the location of the tire pressure sensors on the vehicle. A fourth transponder is not necessary in the remaining wheel well due to the process-of-elimination theory. Once the system knows the location of the first three sensors it assumes the location of the fourth tire pressure sensor. On this vehicle, there is a transponder located in the left front, left rear, and right rear wheelhouse. There is not a transponder located in the right front wheelhouse. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Description > Page 1716 Tire Pressure Monitor Receiver / Transponder: Description and Operation Operation OPERATION On vehicles equipped with the premium TPM system, the Wireless Control Module (WCM), commonly referred to as the Sentry Key Remote Entry Module (SKREEM), uses transponders (trigger modules) located in three of the four wheel wells on the vehicle to provide it with the location of the tire pressure sensors on the vehicle. Like the base system, the WCM receives RF signals from all four rotating wheel speed sensors. When the WCM needs to know which sensor is located at a particular location on the vehicle, it directs the transponder at that location to send out a low frequency signal to excite the nearby sensor. The WCM then receives that excited signal and knows where that sensor is located. This auto-locating process only happens in the first 10 minutes of any WCM cycle while traveling at speeds above 20 mph (32 km/h). (The auto-locating process will start again only if the vehicle has been shut off for approximately 20 minutes or longer). Once the WCM has performed this to the three locations that have transponders, it uses the process-of-elimination theory to know that the fourth sensor ID signal is coming from. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Removal Tire Pressure Monitor Receiver / Transponder: Service and Repair Removal Front FRONT 1. Remove the wheelhouse splash shield at the transponder requiring service. 2. Disconnect the wiring harness connector (2) at the transponder (1). 3. Remove the mounting nuts (3), then remove the transponder (1). Rear REAR 1. Remove the wheelhouse splash shield at the transponder requiring service. 2. Disconnect the wiring harness connector (3) at the transponder (1). 3. Remove the mounting nuts (2), then remove the transponder (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Removal > Page 1719 Tire Pressure Monitor Receiver / Transponder: Service and Repair Installation Front FRONT 1. Position the transponder (1) and install the mounting nuts (3). 2. Connect the wiring harness connector (2) to the transponder (1). 3. Install the wheelhouse splash shield and all components removed to access it. 4. Perform the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests Rear REAR 1. Position the transponder (1) and install the mounting nuts (2). 2. Connect the wiring harness connector (3) to the transponder (1). 3. Install the rear wheelhouse splash shield and all components removed to access it. 4. Perform the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions Tire Pressure Sensor: Service Precautions CAUTION CAUTION: The use of tire sealants is strictly prohibited for vehicles equipped with the Tire Pressure Monitoring system. Tire sealants can clog tire pressure sensors. CAUTION: Any time a sensor is to be installed in a wheel, it is necessary to install a new sensor-to-wheel seal, metal washer and valve stem nut, to ensure air tight sealing. CAUTION: Tire pressure sensor valve stem caps and cores are specially designed for the sensors. Due to risk of corrosion, do not use a standard valve stem cap or core in a tire pressure sensor in place of the original equipment style sensor cap and core. CAUTION: When installing the valve core, be sure to tighten the core to specifications. Overtightening by a little as three or four inch pounds can damage the sensor. CAUTION: Do not attempt to install a tire pressure sensor in an aftermarket wheel. Use tire pressure sensors in original style factory wheels only. If aftermarket wheels are installed, and therefore do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. NOTE: TPM thresholds have been established for the original tire size equipped on the vehicle. Use original size tires only to maintain system accuracy. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Description Tire Pressure Sensor: Description and Operation Description DESCRIPTION On vehicles equipped with Tire Pressure Monitoring (TPM), one tire pressure sensor (6) is mounted to each wheel (5) in place of the traditional tire valve stem. Each sensor has an internal battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the sensor must be replaced. The TPM system operates on a 315 MHz radio frequency. The 315 MHz sensors can be easily identified by a white outline oval (black center) insignia (3) on the sensor body. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Description > Page 1726 The Export TPM system operates on a 433 MHz radio frequency. The 433 MHz sensors can be easily identified by either a solid white oval insignia (3) on the body or... ... a solid white oval insignia (3) with 433 printed in the center. The sensors are identical except for the oval insignia. The 433 MHz sensors can either have a black or grey sensor body. CAUTION: Although 315 MHz and 433 MHz sensors are identical in size and shape, they are not interchangeable. Always make sure the correct sensor is being used. NOTE: Sensors may be identified by valve stem cap color. From the factory, 315 MHz sensors have a gray valve stem cap while 433 MHz sensors have a black valve stem cap. Otherwise, once mounted inside a tire and wheel assembly you are not able to visually tell the difference between a 315 MHz and 433 MHz sensor. At that point, the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool may be used to identify the sensor frequency or the tire can be dismounted allowing visual inspection of the sensor body. The TPM sensors are designed for original style factory wheels. It is not recommended to install a tire pressure sensor in an aftermarket wheel (This could cause sealing and system performance issues). Do not attempt to install a tire pressure sensor in an aftermarket wheel. If aftermarket wheels are installed and do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Description > Page 1727 The serviceable components of the tire pressure sensor are: - Sensor-To-Wheel Seal (2) and Metal Washer (1) - Valve Stem Cap (4) - Valve Stem Core - Valve Stem Nut (with pressed-in washer) (3) NOTE: Any time a sensor is installed on a wheel, a new Sensor-To-Wheel Seal (2), Metal Washer (1) and Valve Stem Nut (3) must be installed to ensure air tight sealing. A service kit is available. The valve stem caps and cores are specifically designed for the tire pressure monitoring sensors. Although similar to standard valve stem caps and cores, they are different. The valve stem cap has a special seal inside to keep moisture and corrosion out. The valve stem core has a special nickel coating to protect from corrosion. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Description > Page 1728 Tire Pressure Sensor: Description and Operation Operation OPERATION The battery operated tire pressure sensor is both a transmitter and a receiver. The TPM sensor can be forced to transmit by using a special tool such as a TPM-RKE Analyzer, or from a transponder. The TPM-RKE Analyzer has the ability to change the sensor's operating mode to PARK MODE and to help diagnose a faulty TPM sensor. Using a TPM-RKE Analyzer can take up to a minute to force a transmission from a sensor. The TPM sensor can be in one of the following operating modes: - SLEEP MODE - This is the operating mode of a new TPM sensor. If placed on the vehicle as a road tire, the sensor will transmit once every 20 seconds when the vehicle is driven at speeds over 15 mph (24 km/h). Driving the vehicle continuously at this speed for more then 4 minutes will change the sensor state to DRIVE MODE. Stopping the vehicle for 20 minutes will change the sensor state to PARK MODE. If the vehicle is not moving, the sensor will only transmit on a pressure change greater then 1 psi (6.9 kPa). - PARK MODE - This is the correct operating mode when the vehicle is not moving. The sensor will transmit once every 13 hours to update the WCM, or will transmit on a 1 psi (6.9 kPa) delta change. The sensors will internally take a measurement of the tire pressure every minute to determine a change in tire pressure. - 30 BLOCK MODE - If the vehicle has been stopped for more then 20 minutes, or if the sensor's operating mode was forced to PARK MODE using a TPM-RKE Analyzer, the sensor's operating mode will transition from PARK MODE to 30 BLOCK MODE once the vehicle is driven over 15 mph. In this mode, the sensor will transmit once every 15 seconds when the vehicle is driven at speeds over 15 mph (24 km/h) for the first 30 transmissions. After about 8 minutes of continuous driving above 15 mph (24 km/h), the sensor's mode will change to DRIVE MODE. - DRIVE MODE - In this mode, the sensor will transmit once every minute when the vehicle is driven at speeds over 15 mph (24 km/h). At any time the vehicle speed drops below 15 mph, the sensor will not transmit. The sensor mode will still be in drive mode when the sensor reaches speeds over 15 mph (24 km/h), unless the vehicle has been stationary for more then 20 minutes. Each sensor's (transmitter) broadcast is uniquely coded so that the wireless control module (WCM) can monitor the state of each of the sensors on the four rotating road wheels. The WCM can automatically learn and store the sensor's ID while driving "within 10 minutes continuously above 15 mph (24 Km/h)" after a sensor has been replaced. The vehicle must be stationary for more then 20 minutes in order to initiate the learning sequence. The WCM can also learn the sensor's ID using the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool following the procedure listed in the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Removal Tire Pressure Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Remove wheel mounting nuts (3), then tire and wheel assembly (1). CAUTION: The cap used on this valve stem contains an O-ring seal to prevent contamination and moisture from entering the valve stem. Retain this valve stem cap for reuse. Do not substitute a regular valve stem cap in its place. CAUTION: The valve stem used on this vehicle is made of aluminum and the core is nickel plated brass. The original valve stem core must be reinstalled and not substituted with a valve stem core made of a different material. This is required to prevent corrosion in the valve stem caused by the different metals. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Removal > Page 1731 3. Dismount tire from wheel following tire changer manufacturers instructions while paying special attention to the following to avoid damaging the pressure sensor: a. When breaking the tire bead loose from the wheel rim, avoid using the Bead Breaker in the area of the sensor. That includes both front and rear beads of the tire. b. When preparing to dismount the tire from the wheel, carefully insert the mounting/dismounting tool at the valve stem ± 10°, then proceed to dismount the tire from the wheel. Use this process on both the upper and lower tire beads. 4. Remove sensor nut (3) retaining sensor to wheel. While removing nut, hold pressure against rear of metal valve stem to keep valve stem from pushing rearward, damaging antenna strap. 5. Remove sensor (1) from wheel (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Removal > Page 1732 Tire Pressure Sensor: Service and Repair Installation INSTALLATION NOTE: Before reinstalling an existing tire pressure sensor, replace seal (2) and metal washer (1) at base of sensor valve stem (6) to ensure proper sealing. 1. Wipe area clean around sensor/valve stem mounting hole in wheel (5). Make sure surface of wheel is not damaged. CAUTION: To avoid damaging sensor antenna strap (1), hold pressure against rear of metal valve stem (2) while sensor is inserted through wheel mounting hole and nut is installed. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Removal > Page 1733 2. Insert sensor (1) through wheel (2) as shown keeping pressure against rear of metal valve stem (See Arrow). Potted side of sensor is to be positioned toward wheel. Do not attempt to mount sensor otherwise, damage may occur. 3. Install sensor nut (with pressed-in washer) (3) by hand. NOTE: Before tightening sensor nut, push downward on sensor housing (2) in an attempt to make it flush with interior contour of wheel (1). 4. While holding sensor in position, tighten sensor nut to 8 Nm (71 in. lbs.). CAUTION: Over-torquing the sensor nut by as little as 12 Nm (106 in. lbs.) may result in sensor separation from the valve stem. Under this condition, the sensor may still function. However, the condition should be corrected immediately. 5. Mount tire on wheel following tire changer manufacturers instructions, paying special attention to the following to avoid damaging tire pressure sensor: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Removal > Page 1734 a. Rotating Wheel Tire Changers - Once the wheel is mounted to the changer, position the sensor valve stem (2) approximately 210° from the head of the changer (located at 1) in a clockwise direction before rotating the wheel (also in a clockwise direction) to mount the tire. Use this procedure on both the upper and lower tire beads. b. Rotating Tool Tire Changers - Position the wheel on the changer so that the sensor valve stem (1) is located approximately 210° clockwise from the installation end of the mounting/dismounting tool (2) once the tool is mounted for tire installation. Make sure the sensor is clear of the lower bead breaker area (3) to avoid damaging the sensor when the breaker rises. Rotate the tool (2) in a counterclockwise direction to mount the tire. Use this procedure on both the upper and lower tire beads. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Removal > Page 1735 6. Adjust air pressure to that listed on Tire Inflation Pressure Label (Placard) provided with vehicle (applied to driver's side B-pillar). Make sure original style and color valve stem cap is securely installed to keep moisture out of sensor. 7. Install tire and wheel assembly (1) on vehicle. Tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 8. Lower vehicle. 9. Perform one of the following to make the system learn the new sensor ID. a. Use the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool to program the WCM/SKREEM with the tire pressure sensor ID. This is part of the TPM Diagnostic Verification Test. b. Once the vehicle has remained stationary for more than 20 minutes, drive vehicle for a minimum of 10 minutes while maintaining a continuous speed above 15 mph (24 km/h). During this time, the system will learn the new sensor ID. This is part of the TPM Diagnostic Verification Test. NOTE: If a sensor cannot be trained, refer to appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front Tire Pressure Monitor Receiver / Transponder: Locations Transponder-Tire Pressure-Left Front Component ID: 361 Component : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Connector: Name : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Color : YELLOW # of pins : 6 Qualifier : (TIRE PRESSURE MONITOR) Pin Description Circuit 1 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 GROUND Z904 20BK/OR 4 GROUND Z904 20BK/OR 5-6-- Component Location - 13 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 1741 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 1742 Tire Pressure Monitor Receiver / Transponder: Locations Transponder-Tire Pressure-Left Rear Component ID: 362 Component : TRANSPONDER-TIRE PRESSURE-LEFT REAR Connector: Name : TRANSPONDER-TIRE PRESSURE-LEFT REAR Color : BLACK # of pins : 6 Qualifier : (TIRE PRESSURE MONITOR) Pin Description Circuit 1 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 GROUND Z904 20BK/OR 4-5-6-- Component Location - 58 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 1743 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 1744 Tire Pressure Monitor Receiver / Transponder: Locations Transponder-Tire Pressure-Right Rear Component ID: 363 Component : TRANSPONDER-TIRE PRESSURE-RIGHT REAR Connector: Name : TRANSPONDER-TIRE PRESSURE-RIGHT REAR Color : BLACK # of pins : 6 Qualifier : (TIRE PRESSURE MONITOR) Pin Description Circuit 1 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 GROUND Z965 20BK/GY 4-5-6 GROUND Z965 20BK/GY Component Location - 59 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 1745 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front Tire Pressure Monitor Receiver / Transponder: Diagrams Transponder-Tire Pressure-Left Front Component ID: 361 Component : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Connector: Name : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Color : YELLOW # of pins : 6 Qualifier : (TIRE PRESSURE MONITOR) Pin Description Circuit 1 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 GROUND Z904 20BK/OR 4 GROUND Z904 20BK/OR 5-6-- Component Location - 13 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 1748 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 1749 Tire Pressure Monitor Receiver / Transponder: Diagrams Transponder-Tire Pressure-Left Rear Component ID: 362 Component : TRANSPONDER-TIRE PRESSURE-LEFT REAR Connector: Name : TRANSPONDER-TIRE PRESSURE-LEFT REAR Color : BLACK # of pins : 6 Qualifier : (TIRE PRESSURE MONITOR) Pin Description Circuit 1 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 GROUND Z904 20BK/OR 4-5-6-- Component Location - 58 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 1750 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 1751 Tire Pressure Monitor Receiver / Transponder: Diagrams Transponder-Tire Pressure-Right Rear Component ID: 363 Component : TRANSPONDER-TIRE PRESSURE-RIGHT REAR Connector: Name : TRANSPONDER-TIRE PRESSURE-RIGHT REAR Color : BLACK # of pins : 6 Qualifier : (TIRE PRESSURE MONITOR) Pin Description Circuit 1 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 GROUND Z965 20BK/GY 4-5-6 GROUND Z965 20BK/GY Component Location - 59 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 1752 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Description Tire Pressure Monitor Receiver / Transponder: Description and Operation Description DESCRIPTION A transponder, sometimes referred to as a trigger module, is located in three of the four wheel wells (behind the wheelhouse splash shields) of a vehicle equipped with Premium TPM. These transponders are used to provide the Wireless Control Module (WCM), commonly referred to as the Sentry Key Remote Entry Module (SKREEM), with the location of the tire pressure sensors on the vehicle. A fourth transponder is not necessary in the remaining wheel well due to the process-of-elimination theory. Once the system knows the location of the first three sensors it assumes the location of the fourth tire pressure sensor. On this vehicle, there is a transponder located in the left front, left rear, and right rear wheelhouse. There is not a transponder located in the right front wheelhouse. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Description > Page 1755 Tire Pressure Monitor Receiver / Transponder: Description and Operation Operation OPERATION On vehicles equipped with the premium TPM system, the Wireless Control Module (WCM), commonly referred to as the Sentry Key Remote Entry Module (SKREEM), uses transponders (trigger modules) located in three of the four wheel wells on the vehicle to provide it with the location of the tire pressure sensors on the vehicle. Like the base system, the WCM receives RF signals from all four rotating wheel speed sensors. When the WCM needs to know which sensor is located at a particular location on the vehicle, it directs the transponder at that location to send out a low frequency signal to excite the nearby sensor. The WCM then receives that excited signal and knows where that sensor is located. This auto-locating process only happens in the first 10 minutes of any WCM cycle while traveling at speeds above 20 mph (32 km/h). (The auto-locating process will start again only if the vehicle has been shut off for approximately 20 minutes or longer). Once the WCM has performed this to the three locations that have transponders, it uses the process-of-elimination theory to know that the fourth sensor ID signal is coming from. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Removal Tire Pressure Monitor Receiver / Transponder: Service and Repair Removal Front FRONT 1. Remove the wheelhouse splash shield at the transponder requiring service. 2. Disconnect the wiring harness connector (2) at the transponder (1). 3. Remove the mounting nuts (3), then remove the transponder (1). Rear REAR 1. Remove the wheelhouse splash shield at the transponder requiring service. 2. Disconnect the wiring harness connector (3) at the transponder (1). 3. Remove the mounting nuts (2), then remove the transponder (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Removal > Page 1758 Tire Pressure Monitor Receiver / Transponder: Service and Repair Installation Front FRONT 1. Position the transponder (1) and install the mounting nuts (3). 2. Connect the wiring harness connector (2) to the transponder (1). 3. Install the wheelhouse splash shield and all components removed to access it. 4. Perform the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests Rear REAR 1. Position the transponder (1) and install the mounting nuts (2). 2. Connect the wiring harness connector (3) to the transponder (1). 3. Install the rear wheelhouse splash shield and all components removed to access it. 4. Perform the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service Precautions Tire Pressure Sensor: Service Precautions CAUTION CAUTION: The use of tire sealants is strictly prohibited for vehicles equipped with the Tire Pressure Monitoring system. Tire sealants can clog tire pressure sensors. CAUTION: Any time a sensor is to be installed in a wheel, it is necessary to install a new sensor-to-wheel seal, metal washer and valve stem nut, to ensure air tight sealing. CAUTION: Tire pressure sensor valve stem caps and cores are specially designed for the sensors. Due to risk of corrosion, do not use a standard valve stem cap or core in a tire pressure sensor in place of the original equipment style sensor cap and core. CAUTION: When installing the valve core, be sure to tighten the core to specifications. Overtightening by a little as three or four inch pounds can damage the sensor. CAUTION: Do not attempt to install a tire pressure sensor in an aftermarket wheel. Use tire pressure sensors in original style factory wheels only. If aftermarket wheels are installed, and therefore do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. NOTE: TPM thresholds have been established for the original tire size equipped on the vehicle. Use original size tires only to maintain system accuracy. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Description and Operation > Description Tire Pressure Sensor: Description and Operation Description DESCRIPTION On vehicles equipped with Tire Pressure Monitoring (TPM), one tire pressure sensor (6) is mounted to each wheel (5) in place of the traditional tire valve stem. Each sensor has an internal battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the sensor must be replaced. The TPM system operates on a 315 MHz radio frequency. The 315 MHz sensors can be easily identified by a white outline oval (black center) insignia (3) on the sensor body. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Description and Operation > Description > Page 1764 The Export TPM system operates on a 433 MHz radio frequency. The 433 MHz sensors can be easily identified by either a solid white oval insignia (3) on the body or... ... a solid white oval insignia (3) with 433 printed in the center. The sensors are identical except for the oval insignia. The 433 MHz sensors can either have a black or grey sensor body. CAUTION: Although 315 MHz and 433 MHz sensors are identical in size and shape, they are not interchangeable. Always make sure the correct sensor is being used. NOTE: Sensors may be identified by valve stem cap color. From the factory, 315 MHz sensors have a gray valve stem cap while 433 MHz sensors have a black valve stem cap. Otherwise, once mounted inside a tire and wheel assembly you are not able to visually tell the difference between a 315 MHz and 433 MHz sensor. At that point, the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool may be used to identify the sensor frequency or the tire can be dismounted allowing visual inspection of the sensor body. The TPM sensors are designed for original style factory wheels. It is not recommended to install a tire pressure sensor in an aftermarket wheel (This could cause sealing and system performance issues). Do not attempt to install a tire pressure sensor in an aftermarket wheel. If aftermarket wheels are installed and do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Description and Operation > Description > Page 1765 The serviceable components of the tire pressure sensor are: - Sensor-To-Wheel Seal (2) and Metal Washer (1) - Valve Stem Cap (4) - Valve Stem Core - Valve Stem Nut (with pressed-in washer) (3) NOTE: Any time a sensor is installed on a wheel, a new Sensor-To-Wheel Seal (2), Metal Washer (1) and Valve Stem Nut (3) must be installed to ensure air tight sealing. A service kit is available. The valve stem caps and cores are specifically designed for the tire pressure monitoring sensors. Although similar to standard valve stem caps and cores, they are different. The valve stem cap has a special seal inside to keep moisture and corrosion out. The valve stem core has a special nickel coating to protect from corrosion. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Description and Operation > Description > Page 1766 Tire Pressure Sensor: Description and Operation Operation OPERATION The battery operated tire pressure sensor is both a transmitter and a receiver. The TPM sensor can be forced to transmit by using a special tool such as a TPM-RKE Analyzer, or from a transponder. The TPM-RKE Analyzer has the ability to change the sensor's operating mode to PARK MODE and to help diagnose a faulty TPM sensor. Using a TPM-RKE Analyzer can take up to a minute to force a transmission from a sensor. The TPM sensor can be in one of the following operating modes: - SLEEP MODE - This is the operating mode of a new TPM sensor. If placed on the vehicle as a road tire, the sensor will transmit once every 20 seconds when the vehicle is driven at speeds over 15 mph (24 km/h). Driving the vehicle continuously at this speed for more then 4 minutes will change the sensor state to DRIVE MODE. Stopping the vehicle for 20 minutes will change the sensor state to PARK MODE. If the vehicle is not moving, the sensor will only transmit on a pressure change greater then 1 psi (6.9 kPa). - PARK MODE - This is the correct operating mode when the vehicle is not moving. The sensor will transmit once every 13 hours to update the WCM, or will transmit on a 1 psi (6.9 kPa) delta change. The sensors will internally take a measurement of the tire pressure every minute to determine a change in tire pressure. - 30 BLOCK MODE - If the vehicle has been stopped for more then 20 minutes, or if the sensor's operating mode was forced to PARK MODE using a TPM-RKE Analyzer, the sensor's operating mode will transition from PARK MODE to 30 BLOCK MODE once the vehicle is driven over 15 mph. In this mode, the sensor will transmit once every 15 seconds when the vehicle is driven at speeds over 15 mph (24 km/h) for the first 30 transmissions. After about 8 minutes of continuous driving above 15 mph (24 km/h), the sensor's mode will change to DRIVE MODE. - DRIVE MODE - In this mode, the sensor will transmit once every minute when the vehicle is driven at speeds over 15 mph (24 km/h). At any time the vehicle speed drops below 15 mph, the sensor will not transmit. The sensor mode will still be in drive mode when the sensor reaches speeds over 15 mph (24 km/h), unless the vehicle has been stationary for more then 20 minutes. Each sensor's (transmitter) broadcast is uniquely coded so that the wireless control module (WCM) can monitor the state of each of the sensors on the four rotating road wheels. The WCM can automatically learn and store the sensor's ID while driving "within 10 minutes continuously above 15 mph (24 Km/h)" after a sensor has been replaced. The vehicle must be stationary for more then 20 minutes in order to initiate the learning sequence. The WCM can also learn the sensor's ID using the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool following the procedure listed in the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Removal Tire Pressure Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Remove wheel mounting nuts (3), then tire and wheel assembly (1). CAUTION: The cap used on this valve stem contains an O-ring seal to prevent contamination and moisture from entering the valve stem. Retain this valve stem cap for reuse. Do not substitute a regular valve stem cap in its place. CAUTION: The valve stem used on this vehicle is made of aluminum and the core is nickel plated brass. The original valve stem core must be reinstalled and not substituted with a valve stem core made of a different material. This is required to prevent corrosion in the valve stem caused by the different metals. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Removal > Page 1769 3. Dismount tire from wheel following tire changer manufacturers instructions while paying special attention to the following to avoid damaging the pressure sensor: a. When breaking the tire bead loose from the wheel rim, avoid using the Bead Breaker in the area of the sensor. That includes both front and rear beads of the tire. b. When preparing to dismount the tire from the wheel, carefully insert the mounting/dismounting tool at the valve stem ± 10°, then proceed to dismount the tire from the wheel. Use this process on both the upper and lower tire beads. 4. Remove sensor nut (3) retaining sensor to wheel. While removing nut, hold pressure against rear of metal valve stem to keep valve stem from pushing rearward, damaging antenna strap. 5. Remove sensor (1) from wheel (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Removal > Page 1770 Tire Pressure Sensor: Service and Repair Installation INSTALLATION NOTE: Before reinstalling an existing tire pressure sensor, replace seal (2) and metal washer (1) at base of sensor valve stem (6) to ensure proper sealing. 1. Wipe area clean around sensor/valve stem mounting hole in wheel (5). Make sure surface of wheel is not damaged. CAUTION: To avoid damaging sensor antenna strap (1), hold pressure against rear of metal valve stem (2) while sensor is inserted through wheel mounting hole and nut is installed. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Removal > Page 1771 2. Insert sensor (1) through wheel (2) as shown keeping pressure against rear of metal valve stem (See Arrow). Potted side of sensor is to be positioned toward wheel. Do not attempt to mount sensor otherwise, damage may occur. 3. Install sensor nut (with pressed-in washer) (3) by hand. NOTE: Before tightening sensor nut, push downward on sensor housing (2) in an attempt to make it flush with interior contour of wheel (1). 4. While holding sensor in position, tighten sensor nut to 8 Nm (71 in. lbs.). CAUTION: Over-torquing the sensor nut by as little as 12 Nm (106 in. lbs.) may result in sensor separation from the valve stem. Under this condition, the sensor may still function. However, the condition should be corrected immediately. 5. Mount tire on wheel following tire changer manufacturers instructions, paying special attention to the following to avoid damaging tire pressure sensor: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Removal > Page 1772 a. Rotating Wheel Tire Changers - Once the wheel is mounted to the changer, position the sensor valve stem (2) approximately 210° from the head of the changer (located at 1) in a clockwise direction before rotating the wheel (also in a clockwise direction) to mount the tire. Use this procedure on both the upper and lower tire beads. b. Rotating Tool Tire Changers - Position the wheel on the changer so that the sensor valve stem (1) is located approximately 210° clockwise from the installation end of the mounting/dismounting tool (2) once the tool is mounted for tire installation. Make sure the sensor is clear of the lower bead breaker area (3) to avoid damaging the sensor when the breaker rises. Rotate the tool (2) in a counterclockwise direction to mount the tire. Use this procedure on both the upper and lower tire beads. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Removal > Page 1773 6. Adjust air pressure to that listed on Tire Inflation Pressure Label (Placard) provided with vehicle (applied to driver's side B-pillar). Make sure original style and color valve stem cap is securely installed to keep moisture out of sensor. 7. Install tire and wheel assembly (1) on vehicle. Tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 8. Lower vehicle. 9. Perform one of the following to make the system learn the new sensor ID. a. Use the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool to program the WCM/SKREEM with the tire pressure sensor ID. This is part of the TPM Diagnostic Verification Test. b. Once the vehicle has remained stationary for more than 20 minutes, drive vehicle for a minimum of 10 minutes while maintaining a continuous speed above 15 mph (24 km/h). During this time, the system will learn the new sensor ID. This is part of the TPM Diagnostic Verification Test. NOTE: If a sensor cannot be trained, refer to appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Technical Service Bulletins > Tire Monitor System - Dashes Displayed Using Spare Tire Spare Tire: Technical Service Bulletins Tire Monitor System - Dashes Displayed Using Spare Tire NUMBER: 22-001-06 REV. B GROUP: Tires & Wheels DATE: August 12, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 22-001-06 REV. A, DATED JUNE 29, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITIONAL MODELS. SUBJECT: Tire Pressure Monitoring System (1PM) Displays Dashes "--" When The Spare Tire Is Used MODELS: 2007 (PM) Caliber 2007 (MK-49) Compass **2007 (JS) **2007 (KA) Nitro** DISCUSSION: If the TPM system detects a low tire, it will set a low tire DTC (C0077 - Low Tire Pressure), notify the customer by illuminating the TPM telltale, and display the low tire pressure values in the EVIC display. Once the low road tire is replaced by the spare tire and the vehicle is driven above 25 MPH (40 KPH) for more than 10 minutes; the TPM system will set an additional DTC (C151C - Tire Pressure Sensor Missing), notify the customer by displaying "CHECK TPM SYSTEM" for 3 seconds, and replaces the low tire pressure value with dashes If: ^ The original tire with pressure sensor remains inside the vehicle or within a valid Radio Frequency range with the WCM (TPM receiver). And: ^ The pressure changes in the low tire by more than 1 PSI or 13 hours expire from the time the low tire event occurred. Then: ^ The dashes will be replaced by the actual low tire pressure value. This low tire / dash "--" cycle will repeat until the pressure is restored in the original tire. NOTE: The spare tire is not equipped with a tire pressure monitoring (TPM) sensor. Do not replace any TPM sensors for this condition. Correct the low tire condition first and then verify that the C151C - Tire Pressure Sensor Missing and the C0077 - Low Tire Pressure DTC change to a stored code. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Technical Service Bulletins > Tire Monitor System - Dashes Displayed Using Spare Tire > Page 1779 Spare Tire: Technical Service Bulletins Tire Monitor System - Displays Dashes When Using Spare NUMBER: 22-001-06 GROUP: Tires & Wheels DATE: February 8, 2006 SUBJECT: Tire Pressure Monitoring System (1PM) Displays Dashes "--" When The Spare Tire Is Used. MODELS: 2007 (PM) Caliber DISCUSSION: If the TPM system detects a low tire, it will set a low tire DTC (C0077 - Low Tire Pressure), notify the customer by illuminating the TPM telltale, and display the low tire pressure values in the EVIC display. Once the low road tire is replaced by the spare tire and the vehicle is driven above 25 MPH (40 KPH) for more than 10 minutes; the TPM system will set an additional DTC (C151C - Tire Pressure Sensor Missing), notify the customer by displaying "CHECK TPM SYSTEM" for 3 seconds, and replaces the low tire pressure value with dashes If: ^ The original tire with pressure sensor remains inside the vehicle or within a valid Radio Frequency range with the WCM (TPM receiver). And: ^ The pressure changes in the low tire by more than 1 PSI or 13 hours expire from the time the low tire event occurred. Then: ^ The dashes will be replaced by the actual low tire pressure value. This low tire / dash "--" cycle will repeat until the pressure is restored in the original tire. NOTE: The spare tire is not equipped with a tire pressure monitoring (TPM) sensor. Do not replace any TPM sensors for this condition. Correct the low tire condition first and then verify that the C151C - Tire Pressure Sensor Missing and the C0077 - Low Tire Pressure DTC change to a stored code. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Chrome Clad Wheel Balancing Information Wheels: Technical Service Bulletins Wheels/Tires - Chrome Clad Wheel Balancing Information NUMBER: 22-002-09 GROUP: Wheels/Tires DATE: July 29, 2009 SUBJECT: Chrome Clad Wheel Adapters For Proper Balancing OVERVIEW: This bulletin describes the use of proper wheel adapters when mounting Chrome Clad wheels to wheel balancing equipment. MODELS: 2004-2008 (CS) Pacifica 2007 - 2009 (D1) Ram Truck (3500 Pick Up) 2007 - 2010 DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2004 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2009-2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2008 - 2010 (JS27) Sebring Convertible 2007 - 2010 (JS41) Sebring/Avenger 2007-2010 (KA) Nitro 2002-2007 (KJ) Liberty 2002 - 2007 (KJ) Cherokee (International Markets) 2008 - 2010 (KK) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005-2010 (ND) Dakota 2007 - 2001 (PM) Caliber 2001 - 2009 (PT) Chrysler PT Cruiser 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2008 - 2010 (RI) Town & Country/Grand Caravan Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Chrome Clad Wheel Balancing Information > Page 1784 2008 - 2010 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005-2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander NOTE: This information applies to any model equipped with Chrome Clad Wheels. DISCUSSION: Models equipped with Chrome Clad wheels require specific piloting on balance equipment to properly center the wheel and prevent damage to the chrome clad surface. The chrome cladding is not removable or replaceable and has cladding tabs that extend into the wheel bore. Traditional high-taper cones will come into contact with the cladding tabs rather than properly seat on the hub bore chamfer. Many modern aluminum wheel designs cannot be mounted with traditional cones. Direct-Fit Collets should be used to properly mount clad wheels on balance equipment (Fig 1). SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: This kit includes the adapters for all Dodge, Chrysler & Jeep models with clad wheels. Individual adapters for specific wheel sizes can be ordered separately. To order a kit or individual adapters, contact Pentastar Service Equipment @ 1-800-223-5623. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1785 Wheels: Specifications WHEEL Torque Specifcations Torque Specifications Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1786 Wheels: Description and Operation WHEEL All vehicles use either steel or cast aluminum drop center wheels. The original equipment wheels are designed for proper operation at all loads up to the specified maximum vehicle capacity. Every wheel has raised sections between the rim flanges (1) and drop well (3) called safety humps (2). In case of air loss, these raised sections help hold the tire in position on the wheel until the vehicle can be brought to a safe stop. When being installed on the wheel, initial inflation of the tire forces the tire bead over these raised sections into place. The wheel studs and nuts are designed for specific wheel applications and must be replaced with equivalent parts. Do not use replacement parts of lesser quality or of a substitute design. All aluminum and steel wheels have wheel stud nuts with an enlarged nose. This enlarged nose is necessary to ensure proper retention of the wheels. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1787 Wheels: Testing and Inspection WHEEL INSPECTION Inspect wheels for: - Excessive runout - Dents, cracks or irregular bends - Damaged wheel stud (lug) holes - Air Leaks NOTE: Do not attempt to repair a wheel by hammering, heating or welding. If a wheel is damaged, an original equipment replacement wheel should be used. When obtaining replacement wheels, they must be equivalent in load carrying capacity. The diameter, width, offset, pilot hole and bolt circle of the wheel should be the same as the original wheel. WARNING: Failure to use equivalent replacement wheels may adversely affect the safety and handling of the vehicle. WARNING: Replacement with used wheels is not recommended. The service history of the wheel may have included severe treatment or very high mileage. The rim could fail without warning. WARNING: DaimlerChrysler Corporation does not recommend that customers use "reconditioned" wheels (wheels that have been damaged and repaired) because they can result in a sudden catastrophic wheel failure which could cause loss of control and result in injury or death. For clarification: - Cosmetic refinishing for the purpose of repairing a superficial flaw is an acceptable procedure providing it is limited to paint or clear coat only, the wheel is not modified in any way, and there is no exposure to paint curing heat over 200 degrees Fahrenheit. - Damaged wheels are those which have been bent, broken, cracked or sustained some other physical damage which may have compromised the wheel structure. - Repaired indicates that the wheel has been modified through bending, welding, heating, straightening, or material removal to rectify damage. - Re-plating of chrome plated wheels is not an acceptable procedure nor is chrome plating of original equipment painted or polished wheels, as this may alter mechanical properties and affect fatigue life. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1788 Wheels: Service and Repair WHEEL AND WHEEL TRIM CARE All wheels and wheel trim, especially aluminum and chrome plated, should be cleaned regularly using mild soap and water to maintain their luster and to prevent corrosion. Wash them with the same soap solution recommended for the body of the vehicle. When cleaning extremely dirty wheels, care must be taken in the selection of tire and wheel cleaning chemicals and equipment to prevent damage to the wheels. Mopar(R) Tire & Wheel Cleaner, Mopar(R) Wheel Treatment or Mopar(R) Chrome Cleaner is recommended. Any of the "DO NOT USE" items listed below can damage wheels and wheel trim. DO NOT USE: - Any abrasive cleaner - Any abrasive cleaning pad (such as steel wool) or abrasive brush - Any cleaner that contains an acid which can react with and discolor the chrome surface. Many wheel cleaners contain acids that can harm the wheel surface. - Oven cleaner - A car wash that uses carbide-tipped wheel cleaning brushes or acidic solutions. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Description and Operation > Front Suspension Wheel Bearing: Description and Operation Front Suspension DESCRIPTION The wheel bearing (5) and hub (3) are pressed into the knuckle (1). The wheel bearing is secured in place using a snap ring. One side of the wheel bearing has an integrated magnetic encoder ring for wheel speed sensor usage as equipped. It is important that the wheel speed sensor magnetic encoder ring (dark band) (3) be positioned to the inside of the knuckle or the wheel speed sensor will not operate correctly. The wheel bearing is a Unit 1 type cartridge bearing that requires no maintenance. The wheel bearing can be serviced separately from the hub. The hub supports the driveline halfshaft outer constant velocity (C/V) joint. Each is splined and meshes in the center of the hub. The outer C/V joint is retained to the hub using a nut. The nut is locked to the outer C/V stub shaft using a cotter pin. The hub has five studs pressed into its flange. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Description and Operation > Front Suspension > Page 1793 Wheel Bearing: Description and Operation Rear Suspension DESCRIPTION The rear wheel bearing and wheel mounting hub used on this vehicle are a one-piece sealed unit or hub and bearing assembly. It is permanently lubricated when assembled and is sealed for life. There is no periodic lubrication or maintenance recommended for these units. The hub and bearing (5) is mounted to the trailing link (1). All vehicles have a magnetic encoder integrated into the right rear hub and bearing for speed sense. Vehicles equipped with antilock brakes have a magnetic encoder integrated into both rear hub and bearings. The encoder works with the rear wheel speed sensors to provide wheel speed signal. The sensor mounts by screw to the rear of the front-wheel-drive hub and bearing while the sensor clips to the rear of the all-wheel-drive hub and bearing. The only serviceable components of the hub and bearing are the wheel mounting studs pressed into the hub. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Front Suspension Wheel Bearing: Testing and Inspection Front Suspension WHEEL BEARING AND HUB NOTE: The wheel bearing is designed to last for the life of the vehicle and requires no type of periodic maintenance. The following procedure may be used for diagnosing the condition of the wheel bearing and hub. 1. Remove the wheel and tire assembly, disc brake caliper and brake rotor. 2. Rotate the wheel hub checking for resistance or roughness. Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing. If the bearing exhibits any of these conditions, the hub bearing will require replacement. Do not attempt to disassemble the bearing for repair. If the wheel bearing is disassembled for any reason, it must be replaced. Damaged bearing seals and the resulting excessive grease loss may also require bearing replacement. Moderate grease weeping from the bearing is considered normal and should not require replacement of the wheel bearing. To diagnose a bent hub, measure hub runout. Refer to Brakes and Traction Control/Testing and inspection. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Front Suspension > Page 1796 Wheel Bearing: Testing and Inspection Rear Suspension HUB AND BEARING NOTE: The wheel bearing is designed to last for the life of the vehicle and requires no type of periodic maintenance. The following procedure may be used for diagnosing the condition of the wheel bearing and hub. 1. Remove the wheel and tire assembly, disc brake caliper and brake rotor. 2. Rotate the wheel hub checking for resistance or roughness. Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing. If the bearing exhibits any of these conditions, the hub and bearing will require replacement. Do not attempt to disassemble the bearing for repair. If the wheel bearing is disassembled for any reason, it must be replaced. Damaged bearing seals and the resulting excessive grease loss may also require bearing replacement. Moderate grease seepage from the bearing is considered normal and should not require replacement of the wheel bearing. To diagnose a bent hub, measure hub runout. Refer to Brakes and Traction Control/Testing and Inspection. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension Wheel Bearing: Service and Repair Front Suspension Removal REMOVAL NOTE: The removal and installation of the wheel bearing and hub from the knuckle is only to be done with the knuckle removed from the vehicle. 1. Remove the steering knuckle from the vehicle. 2. Position the locator block (2) for Fixture, Special Tool 9712, as follows: a. For left side knuckles, place the locator block (2) to the left side (4) on the Fixture. The side of the locator block with the angle cut goes downward, toward the Fixture. Install the mounting screws and tighten them to approximately 54 Nm (40 ft. lbs.). b. For right side knuckles, place the locator block (2) to the right side (3) on the Fixture. The side of the locator block with the angle cut goes downward, toward the Fixture. Install the mounting screws and tighten them to approximately 54 Nm (40 ft. lbs.). 3. Install the knuckle in the Fixture as shown, guiding the steering arm (1) to rest on the locator block (3) and the brake caliper mounting bosses on the two Fixture pins (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 1799 4. Place the Fixture (3) with knuckle in an arbor press. 5. Position Remover/Installer, Special Tool 9712-2 (2), in the small end of the hub. Lower the arbor press ram (1) and remove the hub from the wheel bearing and knuckle. The bearing race will normally come out of the wheel bearing with the hub as it is pressed out of the bearing. 6. Remove the knuckle from the Fixture and turn it over. 7. Remove the snap ring (2) from the knuckle using an appropriate pair of snap ring pliers (1). 8. Place the knuckle back in the Fixture (3) in the arbor press ram. 9. Place Installer (2), Special Tool MD-998334, on the outer race of the wheel bearing. Lower the arbor press ram (1) and remove the wheel bearing from the knuckle. 10. Remove the knuckle and tools from arbor press. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 1800 11. If the bearing race is still pressed onto the hub, install the Bearing Splitter (5), Special Tool 1130, between the hub flange and the bearing inner race (4). 12. Place the hub, bearing race and Bearing Splitter in an arbor press. The press support blocks must not obstruct the wheel hub while it is being pressed out of the bearing race. 13. Place Remover/Installer (2), Special Tool 9712-2, in the end of the hub (3). Lower the arbor press ram (1) and remove the hub from the bearing race. NOTE: For installation, refer to Front Suspension Hub Bearing Installation. Installation INSTALLATION CAUTION: When installing the wheel bearing (1) in the knuckle (2) it is important to place the side of bearing with the wheel speed sensor magnetic encoder ring (dark band) (3) in the knuckle first. Otherwise, the wheel speed sensor will not operate correctly. 1. Wipe the bearing bore of the knuckle clean of any grease or dirt with a clean, dry shop towel. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 1801 2. Place the knuckle in an arbor press supporting the knuckle from underneath using Cup (4), Special Tool 6310-1. 3. Place the NEW wheel bearing (5) magnetic encoder ring side down (see above Caution) into the bore of the knuckle. Be sure the wheel bearing is placed squarely into the bore. 4. Place Receiver (3), Special Tool 8498, larger inside diameter end down over the outer race of the wheel bearing. 5. Place Disc (2), Special Tool 6310-2, into top of Receiver 8498. Lower the arbor press ram (1) and press the wheel bearing into the knuckle until it is bottomed in the bore of the knuckle. 6. Remove the knuckle and tools from the arbor press. 7. Install a NEW snap ring (2) in the knuckle using an appropriate pair of snap ring pliers (1). Make sure the snap ring is fully seated. 8. Place the knuckle in an arbor press. Support the knuckle from underneath using Remover/Installer (3), Special Tool MB-990799, smaller end up against the wheel bearing inner race. 9. Place the hub (4) in the wheel bearing making sure it is square with the bearing inner race. 10. Position Remover/Installer, Special Tool 9712-2 (2), in the end of the hub. Lower the arbor press ram (1) and press the hub into the wheel bearing Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 1802 until it bottoms. 11. Remove the knuckle and tools from the press. 12. Verify the hub turns smoothly without rubbing or binding. 13. Install the knuckle on the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 1803 Wheel Bearing: Service and Repair Rear Suspension All-Wheel-Drive ALL-WHEEL-DRIVE NOTE: Before proceeding, refer to REAR SUSPENSION WARNING. 1. Raise and support the vehicle. 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). 3. Remove the cotter pin (2) from the hub nut (3) on the end of the axle half shaft. 4. While a helper applies the brakes to keep the hub (1) from rotating, remove the hub nut (3) and washer (4) from the axle half shaft. 5. Tap the end of the half shaft inward, loosening it from the hub and bearing. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 1804 6. Remove the disc brake caliper (2) lower guide pin bolt (1). CAUTION: When moving rear brake caliper upward, use extreme care not to damage or overextend the flex hose. Damage may occur. 7. Rotate the caliper upward hinging off the upper guide pin bolt. Rotate the caliper upward just enough to allow brake rotor removal. Hang the caliper assembly in this position using wire or a bungee cord. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 1805 8. Remove any clips (2) retaining the brake rotor (3) to the wheel mounting studs. 9. Slide the brake rotor (3) off the hub and bearing (1). 10. Unclip the wheel speed sensor head (1) from the retainer on the rear of the hub and bearing (2). 11. Remove the four bolts (1) securing the hub and bearing (2) to the trailing link. 12. Remove the hub and bearing. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 1806 Front-Wheel-Drive FRONT-WHEEL-DRIVE NOTE: Before proceeding, refer to REAR SUSPENSION WARNING. 1. Raise and support the vehicle. 2. Remove the wheel mounting nuts (3), then the rear tire and wheel assembly. 3. Remove the disc brake caliper (2) lower guide pin bolt (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 1807 CAUTION: When moving rear brake caliper upward, use extreme care not to damage or overextend the flex hose. Damage may occur. 4. Rotate the caliper upward hinging off the upper guide pin bolt. Rotate the caliper upward just enough to allow brake rotor removal. Hang the caliper assembly in this position using wire or a bungee cord. 5. Remove any clips (2) retaining the brake rotor (3) to the wheel mounting studs. 6. Slide the brake rotor (3) off the hub and bearing (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 1808 7. Remove the screw (1) fastening the wheel speed sensor head (3) in the rear of the hub and bearing (2). 8. Remove the four bolts (1) securing the hub and bearing (2) to the trailing link. 9. Remove the hub and bearing. All-Wheel-Drive ALL-WHEEL-DRIVE Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 1809 1. Slide the hub and bearing over the axle half shaft and position it on the brake support plate and trailing link. 2. Install the four bolts (1) securing the hub and bearing (2) to the trailing link. Tighten the bolts to 105 Nm (77 ft. lbs.). 3. Clip the wheel speed sensor head (1) (flat side to bearing rear) into the retainer on the rear of the hub and bearing (2). 4. Slide the brake rotor (3) over the parking brake shoes and onto the hub and bearing (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 1810 5. Rotate the disc brake caliper downward over the brake rotor and lower part of caliper adapter. 6. Install the disc brake caliper (2) lower guide pin bolt (1). Tighten the guide pin bolt to 60 Nm (44 ft. lbs.). 7. Clean all foreign matter from the threads of the half shaft outer C/V joint. 8. Install the washer (4) and hub nut (3) on the end of the half shaft and snug it. 9. While a helper applies the brakes to keep the hub (1) from rotating, tighten the hub nut (3) to 245 Nm (181 ft. lbs.). 10. Insert the cotter pin (2) through the notches in the nut and the hole in half shaft. If the notches in the nut do not line up with the hole in the half shaft, continue to tighten the nut until they do. Do not loosen the nut. 11. Wrap the cotter pin (2) ends tightly around the lock nut. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 1811 12. Install tire and wheel assembly (1). Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 13. Lower the vehicle. 14. Pump the brake pedal several times to ensure the vehicle has a firm brake pedal before moving it. Front-Wheel-Drive FRONT-WHEEL-DRIVE NOTE: If equipped, make sure the wheel speed sensor mount on the rear of the hub and bearing is directed toward the front of the vehicle. 1. Position the hub and bearing on the brake support plate and trailing link. 2. Install the four bolts (1) securing the hub and bearing (2) to the trailing link. Tighten the bolts to 105 Nm (77 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 1812 3. If equipped, install the wheel speed sensor head (3) into the rear of the hub and bearing (2). 4. Install the wheel speed sensor head mounting screw (1). Tighten the screw to 10 Nm (89 in. lbs.). 5. Slide the brake rotor (3) over the parking brake shoes and onto the hub and bearing (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 1813 6. Rotate the disc brake caliper downward over the brake rotor and lower part of caliper adapter. 7. Install the disc brake caliper (2) lower guide pin bolt (1). Tighten the guide pin bolt to 60 Nm (44 ft. lbs.). 8. Install tire and wheel assembly (1). Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 9. Lower the vehicle. 10. Pump the brake pedal several times to ensure the vehicle has a firm brake pedal before moving it. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Service and Repair > Removal Wheel Cover: Service and Repair Removal REMOVAL 1. Raise and support the vehicle so that tire and wheel assembly clears ground level. CAUTION: When removing the bolt-on wheel cover, do not attempt to pry the wheel cover off the wheel. It is held on by the wheel mounting nuts. 2. Remove the five wheel mounting (lug) nuts (3) from the wheel studs. While removing the nuts, hold the wheel cover (2) in place so it doesn't fall off when the last nut is removed. 3. Remove the wheel cover (2) using care not to let the tire and wheel assembly (1) fall off the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Service and Repair > Removal > Page 1818 Wheel Cover: Service and Repair Installation INSTALLATION WARNING: Installing wheels without good metal-to-metal contact with the mounting surface could cause loosening of the wheel mounting (lug) nuts. This could adversely affect the safety and handling of the vehicle. NOTE: Never use oil or grease on studs or wheel mounting (lug) nuts. 1. With the tire and wheel assembly (1) positioned on the wheel studs without the wheel mounting (lug) nuts installed, align the valve notch in the wheel cover with the valve stem on the wheel and install the wheel cover over the studs. NOTE: Always use the original (OEM) style wheel mounting (lug) nuts. Do not use replacement parts of lesser quality or substitute design. 2. Install and lightly snug all five wheel mounting (lug) nuts (3) Do not tighten at this time. 3. Lower the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Service and Repair > Removal > Page 1819 4. Progressively tighten all wheel mounting (lug) nuts in the proper sequence shown. Tighten the nuts to a final torque of 135 Nm (100 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Hub Nut Tightening Torque ................................................................................................................. .............................................................. 245 Nm (181 ft. lbs.) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications ALUMINUM WHEEL Progressively tighten all wheel mounting nuts in the proper sequence shown. Tighten nuts to a final torque of ............................................................................................................................................................ 135 Nm (100 ft. lbs.) STEEL WHEEL Progressively tighten all wheel mounting (lug) nuts in the proper sequence shown. Tighten the nuts to a final torque of ...................................................................................................................................................... 135 Nm (100 ft. lbs.) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Wheel Fastener: Service and Repair Front Removal REMOVAL NOTE: Use the following procedure to remove one of five studs on one wheel hub. 1. Access and remove front brake rotor. CAUTION: Do not hammer wheel mounting studs out of the hub. Damage to the wheel bearing will occur, leading to premature bearing failure. 2. Install Remover (3), Special Tool 8677, on the hub flange (1) and wheel stud (2). 3. Tighten the Remover, pushing the wheel mounting stud out the rear of the hub flange. When the shoulder of the stud is past the flange, remove the Remover from the hub. 4. Remove the stud from the hub flange. Installation INSTALLATION NOTE: Use the following procedure to install one of five studs on one wheel hub. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 1829 1. Install the NEW wheel mounting stud in the flange of the hub (2) from the rear. 2. Install several washers (1) and a standard wheel mounting (lug) nut (3) on the stud (4). Install the mounting nut so that the flat side of the nut is against the washers to eliminate any binding. 3. Tighten the wheel mounting nut. This will pull the wheel mounting stud into the hub flange. When the head of the stud is fully seated against the rear of the hub flange, remove the wheel mounting nut and washers. 4. Install the brake rotor and all components previously removed to access it. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 1830 Wheel Fastener: Service and Repair Rear Removal REMOVAL NOTE: Use the following procedure to remove one of five studs on one wheel hub. 1. If equipped with rear disc brakes, access and remove brake rotor. 2. If equipped with rear drum brakes, access and remove brake drum. CAUTION: Do not hammer wheel mounting studs out of the hub. Damage to the wheel bearing will occur, leading to premature bearing failure. 3. Install Remover (1), Special Tool 8677, on the hub flange (2) and wheel stud (3). 4. Rotate the hub around until an open spot is found directly behind the wheel stud. 5. Tighten the Remover, pushing the wheel mounting stud out the rear of the hub flange. When the shoulder of the stud is past the flange, remove the Remover from the hub. 6. Remove the stud from the hub flange. Installation INSTALLATION NOTE: Use the following procedure to install one of five studs on one wheel hub. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 1831 1. Install the NEW wheel mounting stud in the flange of the hub (2) from the rear. 2. Install several washers (1) and a standard wheel mounting (lug) nut (3) on the stud (4). Install the mounting nut so that the flat side of the nut is against the washers to eliminate any binding. 3. Tighten the wheel mounting nut. This will pull the wheel mounting stud into the hub flange. When the head of the stud is fully seated against the rear of the hub flange, remove the wheel mounting nut and washers. 4. If equipped with rear disc brakes, install the brake rotor and all components previously removed to access it. 5. If equipped with rear drum brakes, install the brake drum and tire and wheel assembly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Locations > Solenoid-Camshaft 1/1 Position Variable Valve Timing Solenoid: Locations Solenoid-Camshaft 1/1 Position Component ID: 325 Component : SOLENOID-CAMSHAFT 1/1 POSITION Connector: Name : SOLENOID-CAMSHAFT 1/1 POSITION Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 CMP 1/1 CONTROL K76 20LB/WT 2 FUSED MAIN RELAY OUTPUT K343 16BR/YL Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Locations > Solenoid-Camshaft 1/1 Position > Page 1839 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Locations > Solenoid-Camshaft 1/1 Position > Page 1840 Variable Valve Timing Solenoid: Locations Solenoid-Camshaft 1/2 Position Component ID: 326 Component : SOLENOID-CAMSHAFT 1/2 POSITION Connector: Name : SOLENOID-CAMSHAFT 1/2 POSITION Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 CMP 1/2 CONTROL K276 20DB/WT 2 FUSED MAIN RELAY OUTPUT K343 16BR/YL Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Locations > Solenoid-Camshaft 1/1 Position > Page 1841 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Diagrams > Solenoid-Camshaft 1/1 Position Variable Valve Timing Solenoid: Diagrams Solenoid-Camshaft 1/1 Position Component ID: 325 Component : SOLENOID-CAMSHAFT 1/1 POSITION Connector: Name : SOLENOID-CAMSHAFT 1/1 POSITION Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 CMP 1/1 CONTROL K76 20LB/WT 2 FUSED MAIN RELAY OUTPUT K343 16BR/YL Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Diagrams > Solenoid-Camshaft 1/1 Position > Page 1844 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Diagrams > Solenoid-Camshaft 1/1 Position > Page 1845 Variable Valve Timing Solenoid: Diagrams Solenoid-Camshaft 1/2 Position Component ID: 326 Component : SOLENOID-CAMSHAFT 1/2 POSITION Connector: Name : SOLENOID-CAMSHAFT 1/2 POSITION Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 CMP 1/2 CONTROL K276 20DB/WT 2 FUSED MAIN RELAY OUTPUT K343 16BR/YL Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Diagrams > Solenoid-Camshaft 1/1 Position > Page 1846 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Description and Operation > Description Variable Valve Timing Solenoid: Description and Operation Description DESCRIPTION Variable valve timing solenoid assembly. The solenoid receives pulse width modulation signal and the current is controlled within 0 ma to 1000 ma. The spool position is controllable at any position to control supply of oil between the advance and retard ports. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Description and Operation > Description > Page 1849 Variable Valve Timing Solenoid: Description and Operation Operation OPERATION There is both an Intake and an exhaust camshaft sensor on vehicles equipped with a World Engine. The variable valve timing system used on World Engines requires the exact position of both the intake and exhaust camshaft. The GPEC1 uses camshaft sensor data along with crankshaft data to determine the actual position of the camshafts. Intake and exhaust phaser oil control valves are required on World Engine vehicles using variable valve timing. The oil valves direct oil to the Intake and exhaust phasers. Oil pressure in the phasers moves the camshafts to an advanced or retarded position. To resolve this inherent conflict between optimum high and low speed valve timing, the GPEC1 controlled engine uses a variable valve timing system. The variable valve timing system advances and retards valve timing by rotating the position of both the intake and exhaust camshafts. With this system, the intake valve opening can range from 80 to 120 crankshaft degrees after Top Dead Center. Likewise, the exhaust valve opening can range from 85 to 120 crankshaft degrees before Top Dead Center. This degree of flexibility provides many benefits, including: Improved Engine Performance, Increased Fuel Economy, Improved Idle Stability and Decreased Engine Emissions. In non operating condition, the camshaft stays in lockpin position of cam phases. This is 120 degrees ATDC for intake camshaft and 120 degrees BTDC for exhaust camshaft. The variable valve timing system is electronically controlled and hydraulically operated. The GPEC1 receives information from many sensors to determine the optimum valve timing. It then pulse-width modulates oil control valves which direct oil to the cam phasers. The cam phasers use oil pressure to rotate the intake and exhaust camshafts. The rotation of the camshafts is referred to as cam phasing. Before the GPEC1 can begin commanding the camshaft phasing, several enabling conditions must be met: - The engine oil temperature must be at least -6.6° C (20° F) - The oil control valve coil temperature must be less than 140° C (284° F) - Engine speed must be at least 600 to 1000 rpm to achieve minimum oil pressure. - Battery voltage must be at least 10 volts - And there must be no camshaft or crankshaft sensor faults, engine timing faults, or oil control valve faults First we will examine variable valve timing enabling conditions, and then we will take a closer look at the inputs and outputs of the system: - Accelerator pedal position sensor - Oil temperature sensor - Map sensor - Intake cam sensor - Exhaust cam sensor - Crankshaft sensor - GPEC1 - Exhaust phaser oil control valve - Intake phaser oil control valve - Inputs - Engine control module - Outputs - Sensed battery voltage A minimum oil temperature is required to enable variable valve timing operation. Oil temperature and viscosity also have an impact on the operation of variable valve timing after start-up. Oil is used to control the movement of the camshafts. An incorrect oil viscosity could adversely affect the operation of the system or even render the system inoperative. It may even set a fault code. The accelerator pedal position sensor indicates how far the driver wants to open the throttle plate. The GPEC1 calculates an initial camshaft set point based on whether the accelerator pedal is at part throttle or wide open throttle. The MAP sensor provides information regarding engine load. Sensed battery voltage provides information regarding current system voltage. Sensed battery voltage must be at least 10 volts in order for the oil control valves to function properly. This information allows the GPEC1 to adjust camshaft timing to achieve the best fuel economy, the best engine performance or a combination of both. The hall-effect crankshaft sensor provides RPM information and determines when the number one piston is approaching Top Dead Center. The sensor generates a signal as the tone wheel, attached to the crankshaft, rotates. The tone wheel has 60 teeth minus two. When the gap, created by the missing teeth passes by the sensor, a signal is produced that indicates the number one piston is at Top Dead Center. The GPEC1 uses crankshaft sensor data along with camshaft data to determine the actual position of the camshaft. There are two hall-effect camshaft sensors on engines equipped with variable valve timing. The GPEC1 uses camshaft sensor data along with crankshaft data to determine the actual position of the camshaft. The GPEC1 individually controls each valve. It sends a pulse width modulated signal to move a spool within the outer casing of the valve. Depending upon spool movement, oil is directed through the passages to advance or retard cam timing. The oil control valve also has a special cleaning strategy at Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Description and Operation > Description > Page 1850 key-on. The cleaning strategy is known as "debris crush mode". At key-on the GPEC1 cycles the oil control valve on and off several (5) times to crush any debris in the oil control valve and prevent the spool valve from sticking. In non operating condition, the camshaft stays in lockpin position of cam phases. This is 120 degrees ATDC for intake camshaft and 120 degrees BTDC for exhaust camshaft. There are two oil control valves. One valve directs oil to the intake cam phaser, the other valve directs oil to the exhaust cam phaser. The valves are designed and function in the same manner. The outer casing of each oil valve has five oil passages. A passage for pressurized supply oil. A passage to the advance chamber of the cam phaser. A passage to the retard chamber of the cam phaser. A passage for oil return from the advance chamber of the cam phaser. A passage for oil return from the retard chamber of the cam phaser. Oil flows through the passages and applies pressure to the cam phasers to change cam timing. There are two cam phasers. One phaser controls the position of the intake camshaft. The other phaser controls the position of the exhaust camshaft. The phasers consist of a sprocket, a rotor vane, and a housing or stator. The exhaust cam phaser also consists of a front bushing and spring. We will discuss the purpose and function of the bushing and spring later. The housing is bolted and permanently fixed to the camshaft sprocket, while the rotor vane is bolted and permanently fixed to the camshaft. With this design, any movement of the rotor vane in relation to the housing will also move the camshaft. The phaser and sprocket are serviced as an assembly. Camshaft and crankshaft sensors provide feedback to the GPEC1 regarding the actual position of the camshafts. The GPEC1 then compares the actual camshaft positioning with desired positioning. If the desired positioning is not achieved within a specified time, during the second key cycle a trouble code is set. There are six new diagnostic trouble codes available to help you determine if the control circuit from the GPEC1 to the oil control valve is intact and operating properly. The codes identify whether the control circuit is open, shorted to ground, or shorted to power. Three trouble codes are related to intake camshaft positioning, the other three codes are specific to exhaust camshaft positioning. The oil control valve contains both electrical and mechanical components. It is electrically controlled by the GPEC1. The electrical current that energizes the coil results in mechanical motion of the spool valve. It is possible to verify both the electrical and mechanical operation of the valve. The oil control valve consists of a coil that is energized to move a spool within an outer casing. The condition of the coil can be tested with a Digital Volt Ohmmeter or DVOM. With the DVOM set to measure resistance, check the coil for an open, a short to ground, or excessive resistance. The correct resistance value of the coil is between 6 and 8 ohms. The mechanical operation of the oil control valve can be tested using actuator commands on the scan tool. Remove the oil control valve, then navigate to the actuator menu and select the oil control valve. Use commands to activate the valve and watch as the spool valve moves back and forth inside the casing. Because the cam phasers are hydraulically operated by engine oil, the condition of the oil is very important. The oil must be of the correct viscosity, not obstructed by debris, to maintain correct pressure. Maintaining the correct oil viscosity is critical to the operation of the variable valve timing system. The wrong oil viscosity may cause the variable valve timing to malfunction and trouble codes to set. The correct oil viscosity for this system is 5W20. Oil must be clean, unobstructed and free to flow through the variable valve timing system. Oil could become obstructed in oil passages located in the cylinder head, cylinder block, or even in the oil screen. In the event oil flow is obstructed, further diagnosis or disassembly may be required to pin point the source of the obstruction. The variable valve timing system relies on oil pressure to advance or retard the position of the camshaft. Insufficient oil pressure will adversely affect the operation of variable valve timing. The minimum oil pressure for this system is 15 psi at normal operating temperature. Though not directly used to change camshaft positioning, the oil screen is an important component of the variable valve timing system. It helps to remove debris going to the variable valve timing components. The oil screen is located in the cylinder block, immediately below the cylinder head. Oil must pass through the oil screen before entering the oil control valve. The cylinder head must be removed to service the oil screen. The intention is not to service the oil screen during vehicle life. How the cam phaser works. The cam phaser assembly has eight separate chambers; four advance chambers and four retard chambers. When camshaft advance is requested, oil enters all four advance chambers and exerts force on the rotor vane. Because the rotor vane is bolted to the camshaft, the entire camshaft profile moves along with the rotor vane. At the same time, oil is forced out of the retard chambers. When camshaft retard is requested oil enters the retard chambers to move the camshaft in the opposite direction. There is a lock pin on one side of the rotor vane that fits inside a recessed area in the housing. The lock pin ensures that the default position of the intake cam phaser is 120 crankshaft degrees full retard and the default position of the exhaust cam phaser is 120 crankshaft degrees full advance. When the engine is turned off, rotational force and inertia move the intake camshaft and rotor vane toward the retard position. The exhaust cam phaser includes a spring and bushing to work against the rotational force of the engine, allowing the exhaust cam phaser to lock in the fully advanced position. Under most conditions the cam phasers are returned to lock pin position when the engine is turned off. In the unique condition of an engine stall, which abruptly shuts off the engine, the cam phasers may not return to the lock pin position. In this case, the phasers will return to the lock pin position at the next start-up. Lock pin position is the most ideal cam timing for idle stability. When engine rpm exceeds approximately 600 to 1000 rpm, oil pressure unlocks the pins and variable valve timing resumes. Once enabling conditions are met, the GPEC1 uses input from sensors to calculate optimum valve timing. There are four preprogrammed modes from which the GPEC1 bases initial valve timing. - Starting - Idle or Part throttle - Wide open throttle - Limp-in or Default From each preprogrammed mode, the GPEC1 adjusts valve timing based on operating conditions. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Description and Operation > Description > Page 1851 GPEC1 has calculated optimum intake valve timing of 112 degrees after Top Dead Center and optimum exhaust valve timing of 97 degrees before Top Dead Center. The GPEC1 pulse width modulates the oil control valves to advance or retard the camshaft to their desired location. The spool valve inside the intake oil control valve is energized and moves to allow pressurized oil into the advance chambers of the intake cam phaser. At the same time, the spool valve inside the exhaust oil control valve is energized and moves to allow pressurized oil into the retard chambers of the exhaust cam phaser. Oil enters the advance chambers of the intake phaser and the retard chambers of the exhaust phaser. Oil pressure releases the lock pin from its locked position and pushes against the rotor vane. Both the rotor vanes are moved, advancing the intake camshaft and retarding the exhaust camshaft. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Service and Repair > Variable Valve Timing Solenoid - Removal Variable Valve Timing Solenoid: Service and Repair Variable Valve Timing Solenoid - Removal Front Solenoid 1/1 FRONT SOLENOID 1/1 1. Disconnect negative battery cable. 2. Remove engine cover. 3. Rotate hose clamp out of way. 4. Disconnect oil pressure sensor electrical connector. 5. Remove oil pressure sensor. 6. Disconnect variable valve timing solenoid electrical connector. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Service and Repair > Variable Valve Timing Solenoid - Removal > Page 1854 7. Remove variable valve timing solenoid mounting bolt. 8. Pull solenoid straight out of cylinder head. Rear Solenoid 1/2 REAR SOLENOID 1/2 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Service and Repair > Variable Valve Timing Solenoid - Removal > Page 1855 1. Disconnect negative battery cable. 2. Remove engine cover. 3. Disconnect variable valve timing solenoid electrical connector. 4. Remove variable valve timing solenoid mounting bolt. 5. Pull solenoid straight out of cylinder head. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Service and Repair > Variable Valve Timing Solenoid - Removal > Page 1856 Variable Valve Timing Solenoid: Service and Repair Variable Valve Timing Solenoid - Installation Front Solenoid 1/1 FRONT SOLENOID 1/1 1. Solenoid for front location 1/1. Note mounting tab location is different between front and rear solenoids. 2. Install solenoid into cylinder head. 3. Install mounting bolt and tighten to 12 Nm (9 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Service and Repair > Variable Valve Timing Solenoid - Removal > Page 1857 4. Install oil pressure sensor. 5. Connect electrical connector to oil pressure sensor. 6. Connect electrical connector to Variable valve timing solenoid. 7. Connect negative battery cable. 8. Install engine cover. Rear Solenoid 1/2 REAR SOLENOID 1/2 1. Rear variable valve timing solenoid. Note mounting tab location is different between front and rear solenoids. 2. Install solenoid into cylinder head. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Service and Repair > Variable Valve Timing Solenoid - Removal > Page 1858 3. Install mounting bolt and tighten to 12 Nm (9 ft. lbs.). 4. Connect electrical connector to Variable valve timing solenoid. 5. Connect negative battery cable. 6. Install engine cover. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications Compression Pressure Metric ................................................................................................................................................... ...................................................... 1172-1551 kPa Standard .............................................................. ............................................................................................................................................ 170-225 psi Compression should not be less than 1034 kPa (150 psi) and not vary more than 25 percent from cylinder to cylinder. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 1862 Compression Check: Testing and Inspection CYLINDER COMPRESSION PRESSURE TEST The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine reaches normal operating temperature. Select a route free from traffic and other forms of congestion, observe all traffic laws, and accelerate through the gears several times briskly. 3. Remove engine cover. 4. Disconnect coil electrical connectors and remove coils. 5. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing indicators fouled, hot, oily, etc. Record cylinder number of spark plug for future reference. 6. Disconnect injector electrical connectors. 7. Be sure throttle blade is fully open during the compression check. 8. Insert compression gauge adaptor 8116 or the equivalent, into the #1 spark plug hole in cylinder head. Connect the 0-500 psi (Blue) pressure transducer CH7059 with cable adaptors to the DRBIII(R). 9. Crank engine until maximum pressure is reached on gauge. Record this pressure as #1 cylinder pressure. 10. Repeat the previous step for all remaining cylinders. 11. Compression should not be less than 1034 kPa (150 psi) and not vary more than 25 percent from cylinder to cylinder. 12. If one or more cylinders have abnormally low compression pressures, repeat the compression test. 13. If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem in the cylinder in question. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Technical Service Bulletins > Recalls for Camshaft Bearing: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque Technical Service Bulletin # F38 Date: 061001 Campaign - Engine Camshaft Cap Bolt Torque October 2006 Dealer Service Instructions for: Customer Satisfaction Notification F38 Engine Camshaft Cap Bolts Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) # 06-026 has been cancelled. Models 2007 (PM) Dodge Caliber 2007 (MK) Jeep(R) Compass NOTE: This notification applies only to the above vehicles with an engine build date code through TxxP11596 (Txx=traceability identifier [ignore], P1 = plant code, 159=Julian date for June 8, and, 6=2006). The date code is on the bar code label affixed to the front of the cylinder head cover. IMPORTANT: Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The engine camshaft cap bolts on about 250 of the above vehicles may not have been adequately tightened. This can cause damage to the camshaft bearing and/or the camshaft. Repair The # 1 engine exhaust camshaft bearing position must be inspected and the # 1 camshaft cap bolts must be tightened to specification. Parts Information IMPORTANT: Due to the likelihood that the required Mopar Engine Sealant RTV is already in your parts inventory, no Engine Sealant RTV will be distributed to involved dealers initially. Parts may be ordered as needed to support scheduled repairs. Each tube of sealant is sufficient to complete about 30 vehicles. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Technical Service Bulletins > Recalls for Camshaft Bearing: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque > Page 1872 Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers should perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this notification only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure Engine Camshaft Cap Inspection and Bolt Tightening: 1. Discharge the fuel system pressure as follows: a. Remove the lower rear seat cushion. b. Remove the fuel pump module cover. c. Disconnect the electrical connector to the fuel pump module. d. Start and run engine until it stalls. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Technical Service Bulletins > Recalls for Camshaft Bearing: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque > Page 1873 e. Attempt restarting engine until it will no longer run. f. Turn ignition key to OFF position. 2. Remove air inlet duct over the battery. 3. Disconnect the battery. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 4. Remove the engine cover and the plastic retainers on the valve cover studs. 5. Disconnect the electrical connectors on the ignition coils. 6. Disconnect the PCV and make-up air hoses from cylinder head cover. 7. Unfasten the electrical harness and its retainer clips from the cylinder head cover studs. 8. Disconnect the fuel line at the engine fuel rail. 9. Use compressed air to blow dirt and debris off the cylinder head cover. 10. Remove the cylinder head cover, ignition coils, bolts and studs as a complete assembly. CAUTION: Do not remove the coils from the cylinder head cover at this time to minimize dirt from entering the engine during disassembly. 11. On the bench, remove the four ignition coils from the cylinder head cover. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Technical Service Bulletins > Recalls for Camshaft Bearing: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque > Page 1874 12. Inspect the rear of the # 1 camshaft bearing cap at the exhaust camshaft (Figure 1): If the split line of the bearings and the split line of the bearing cap-to-cylinder head are parallel to each other, continue with Step 13. If the split line of the bearings and the split line of the bearing cap-to-cylinder head are NOT parallel to each other, (the bearing has rotated) contact the STAR Center for further assistance. 13. Tighten each of the front camshaft bearing cap bolts to 20 ft.lbs. (27 N.m) in the following order (Figure 2): a. Exhaust side outside bolt (1). b. Intake side outside bolt (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Technical Service Bulletins > Recalls for Camshaft Bearing: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque > Page 1875 c. Exhaust side middle bolt (3). d. Intake side middle bolt (4). 14. Clean all RTV from the cylinder head surface and wipe the surface with a clean cloth. 15. With a clean cloth, wipe the cylinder head cover gasket and inspect for damage (cuts, tears or voids). If damaged, replace with PN 04884765AA center gasket and/or PN 04884762AA perimeter gasket. 16. Apply a 1/8" (3mm) bead of Mopar Engine Sealant RTV to cylinder head/front cover T-joint (Figure 3). 17. Position the cylinder head cover on the engine and install cylinder head cover studs as shown. (Figure 4). 18. Position the cylinder head cover on the cylinder head and install all bolts. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Technical Service Bulletins > Recalls for Camshaft Bearing: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque > Page 1876 19. Tighten the cylinder head cover fasteners in two steps following the sequence as shown in Figure 5: a. Tighten all fasteners to 44 in. lbs. (5 N.m). b. Tighten all bolts to 90 in. lbs. (10 N.m). 20. Install the four ignition coils. Tighten fasteners to 70 in. lbs. (8 N.m). 21. Connect the fuel line to the engine fuel rail. 22. Install the harness and its retainer clips onto the cylinder head cover studs. 23. Remove the plastic retainers (if any) from the engine cover and install the four retainers onto the appropriate studs of the cylinder head cover. 24. Connect the PCV and make-up air hoses to the cylinder head cover. 25. Install the engine cover. Check all four mounting grommets for proper engagement to the plastic retainers. 26. Connect the fuel pump harness connector to the fuel pump. 27. Install the fuel pump access cover and tighten the screw. 28. Install the rear seat lower cushion. 29. Connect the battery. 30. Install the air inlet duct over the battery. NOTE: Due to the fuel line pressure discharge procedure, a Diagnostic Trouble Code (DTC) may be set in some modules (PCM, TCV, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Connect the StarSCAN tool to the vehicle. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Technical Service Bulletins > Recalls for Camshaft Bearing: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque > Page 1877 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Bearing: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque Technical Service Bulletin # F38 Date: 061001 Campaign - Engine Camshaft Cap Bolt Torque October 2006 Dealer Service Instructions for: Customer Satisfaction Notification F38 Engine Camshaft Cap Bolts Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) # 06-026 has been cancelled. Models 2007 (PM) Dodge Caliber 2007 (MK) Jeep(R) Compass NOTE: This notification applies only to the above vehicles with an engine build date code through TxxP11596 (Txx=traceability identifier [ignore], P1 = plant code, 159=Julian date for June 8, and, 6=2006). The date code is on the bar code label affixed to the front of the cylinder head cover. IMPORTANT: Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The engine camshaft cap bolts on about 250 of the above vehicles may not have been adequately tightened. This can cause damage to the camshaft bearing and/or the camshaft. Repair The # 1 engine exhaust camshaft bearing position must be inspected and the # 1 camshaft cap bolts must be tightened to specification. Parts Information IMPORTANT: Due to the likelihood that the required Mopar Engine Sealant RTV is already in your parts inventory, no Engine Sealant RTV will be distributed to involved dealers initially. Parts may be ordered as needed to support scheduled repairs. Each tube of sealant is sufficient to complete about 30 vehicles. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Bearing: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque > Page 1883 Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers should perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this notification only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure Engine Camshaft Cap Inspection and Bolt Tightening: 1. Discharge the fuel system pressure as follows: a. Remove the lower rear seat cushion. b. Remove the fuel pump module cover. c. Disconnect the electrical connector to the fuel pump module. d. Start and run engine until it stalls. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Bearing: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque > Page 1884 e. Attempt restarting engine until it will no longer run. f. Turn ignition key to OFF position. 2. Remove air inlet duct over the battery. 3. Disconnect the battery. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 4. Remove the engine cover and the plastic retainers on the valve cover studs. 5. Disconnect the electrical connectors on the ignition coils. 6. Disconnect the PCV and make-up air hoses from cylinder head cover. 7. Unfasten the electrical harness and its retainer clips from the cylinder head cover studs. 8. Disconnect the fuel line at the engine fuel rail. 9. Use compressed air to blow dirt and debris off the cylinder head cover. 10. Remove the cylinder head cover, ignition coils, bolts and studs as a complete assembly. CAUTION: Do not remove the coils from the cylinder head cover at this time to minimize dirt from entering the engine during disassembly. 11. On the bench, remove the four ignition coils from the cylinder head cover. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Bearing: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque > Page 1885 12. Inspect the rear of the # 1 camshaft bearing cap at the exhaust camshaft (Figure 1): If the split line of the bearings and the split line of the bearing cap-to-cylinder head are parallel to each other, continue with Step 13. If the split line of the bearings and the split line of the bearing cap-to-cylinder head are NOT parallel to each other, (the bearing has rotated) contact the STAR Center for further assistance. 13. Tighten each of the front camshaft bearing cap bolts to 20 ft.lbs. (27 N.m) in the following order (Figure 2): a. Exhaust side outside bolt (1). b. Intake side outside bolt (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Bearing: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque > Page 1886 c. Exhaust side middle bolt (3). d. Intake side middle bolt (4). 14. Clean all RTV from the cylinder head surface and wipe the surface with a clean cloth. 15. With a clean cloth, wipe the cylinder head cover gasket and inspect for damage (cuts, tears or voids). If damaged, replace with PN 04884765AA center gasket and/or PN 04884762AA perimeter gasket. 16. Apply a 1/8" (3mm) bead of Mopar Engine Sealant RTV to cylinder head/front cover T-joint (Figure 3). 17. Position the cylinder head cover on the engine and install cylinder head cover studs as shown. (Figure 4). 18. Position the cylinder head cover on the cylinder head and install all bolts. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Bearing: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque > Page 1887 19. Tighten the cylinder head cover fasteners in two steps following the sequence as shown in Figure 5: a. Tighten all fasteners to 44 in. lbs. (5 N.m). b. Tighten all bolts to 90 in. lbs. (10 N.m). 20. Install the four ignition coils. Tighten fasteners to 70 in. lbs. (8 N.m). 21. Connect the fuel line to the engine fuel rail. 22. Install the harness and its retainer clips onto the cylinder head cover studs. 23. Remove the plastic retainers (if any) from the engine cover and install the four retainers onto the appropriate studs of the cylinder head cover. 24. Connect the PCV and make-up air hoses to the cylinder head cover. 25. Install the engine cover. Check all four mounting grommets for proper engagement to the plastic retainers. 26. Connect the fuel pump harness connector to the fuel pump. 27. Install the fuel pump access cover and tighten the screw. 28. Install the rear seat lower cushion. 29. Connect the battery. 30. Install the air inlet duct over the battery. NOTE: Due to the fuel line pressure discharge procedure, a Diagnostic Trouble Code (DTC) may be set in some modules (PCM, TCV, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Connect the StarSCAN tool to the vehicle. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Bearing: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque > Page 1888 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Technical Service Bulletins > Page 1889 Camshaft Bearing: Specifications Camshaft Bearing Cap-Bolts M6 Bolts ............................................................................................................................................... ............................................. 12 Nm (105 in. lbs.) M8 Bolts ................................................................ .............................................................................................................................. 34 Nm (25 ft. lbs.) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Description and Operation > Variable Valve Timing Assembly - Description Camshaft Gear/Sprocket: Description and Operation Variable Valve Timing Assembly - Description DESCRIPTION The world engine is equipped with Variable Valve Timing (VVT). This system advances and/or retards intake and/or exhaust camshaft timing to improve engine performance, mid-range torque, idle quality, fuel economy, and reduce emissions. The camshaft sprockets are integrated with the VVT assemblies and are serviced as an assembly. VVT assemblies are sometimes referred to as camshaft phasers. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Description and Operation > Variable Valve Timing Assembly - Description > Page 1894 Camshaft Gear/Sprocket: Description and Operation Variable Valve Timing Assembly - Operation OPERATION The Variable Valve Timing (VVT) assemblies are actuated with engine oil pressure. The oil flow to the VVT assemblies are controlled by two Oil Control Valves (OCV). There is an OCV and Camshaft Position Sensor (CMP) for each camshaft. The OCV's consist of a Pulse Width Modulated (PWM) solenoid and a spool valve. The PCM actuates the OCV to control oil flow through the spool valve into the VVT assemblies. The VVT assembly consists of a rotor, stator, and sprocket. The stator is connected to the timing chain through the sprocket. The rotor is connected to the camshaft. Oil flow in to the VVT assembly rotates the rotor with respect to the stator, thus rotating the camshaft with respect to the timing chain. Thus, the VVT assemblies change valve timing by changing the relationship between the camshaft and the timing chain. An infinitely variable valve timing position can be achieved within the limits of the hardware. The CMP monitors the position of the camshaft with respect to the crankshaft and provides feedback to the PCM. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Service and Repair > Camshaft Sprockets - Removal Camshaft Gear/Sprocket: Service and Repair Camshaft Sprockets - Removal REMOVAL NOTE: Camshaft phaser and camshaft sprocket are supplied as an assembly, do not attempt to disassemble. 1. Remove camshafts. 2. Remove camshaft phaser (2) retaining bolt while holding the camshaft in place with a wrench (1) on the camshaft flats. 3. Remove phaser (2) assembly from camshaft. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Service and Repair > Camshaft Sprockets - Removal > Page 1897 Camshaft Gear/Sprocket: Service and Repair Camshaft Sprockets - Installation INSTALLATION CAUTION: Do not use an impact wrench to tighten camshaft sprocket bolts. Damage to the camshaft-to-sprocket locating dowel pin and camshaft phaser may occur. 1. Install phaser (2) assembly on camshaft. NOTE: Make sure the dowel is seated in the dowel hole and not in a oil feed hole. The dowel hole is larger than the 4 oil feed holes. 2. Install phaser retaining bolt and torque while holding camshaft in place with a wrench (1). 3. Install camshafts. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Technical Service Bulletins > Recalls for Camshaft: > F38 > Oct > 06 > Campaign Engine Camshaft Cap Bolt Torque Technical Service Bulletin # F38 Date: 061001 Campaign - Engine Camshaft Cap Bolt Torque October 2006 Dealer Service Instructions for: Customer Satisfaction Notification F38 Engine Camshaft Cap Bolts Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) # 06-026 has been cancelled. Models 2007 (PM) Dodge Caliber 2007 (MK) Jeep(R) Compass NOTE: This notification applies only to the above vehicles with an engine build date code through TxxP11596 (Txx=traceability identifier [ignore], P1 = plant code, 159=Julian date for June 8, and, 6=2006). The date code is on the bar code label affixed to the front of the cylinder head cover. IMPORTANT: Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The engine camshaft cap bolts on about 250 of the above vehicles may not have been adequately tightened. This can cause damage to the camshaft bearing and/or the camshaft. Repair The # 1 engine exhaust camshaft bearing position must be inspected and the # 1 camshaft cap bolts must be tightened to specification. Parts Information IMPORTANT: Due to the likelihood that the required Mopar Engine Sealant RTV is already in your parts inventory, no Engine Sealant RTV will be distributed to involved dealers initially. Parts may be ordered as needed to support scheduled repairs. Each tube of sealant is sufficient to complete about 30 vehicles. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Technical Service Bulletins > Recalls for Camshaft: > F38 > Oct > 06 > Campaign Engine Camshaft Cap Bolt Torque > Page 1906 Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers should perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this notification only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure Engine Camshaft Cap Inspection and Bolt Tightening: 1. Discharge the fuel system pressure as follows: a. Remove the lower rear seat cushion. b. Remove the fuel pump module cover. c. Disconnect the electrical connector to the fuel pump module. d. Start and run engine until it stalls. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Technical Service Bulletins > Recalls for Camshaft: > F38 > Oct > 06 > Campaign Engine Camshaft Cap Bolt Torque > Page 1907 e. Attempt restarting engine until it will no longer run. f. Turn ignition key to OFF position. 2. Remove air inlet duct over the battery. 3. Disconnect the battery. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 4. Remove the engine cover and the plastic retainers on the valve cover studs. 5. Disconnect the electrical connectors on the ignition coils. 6. Disconnect the PCV and make-up air hoses from cylinder head cover. 7. Unfasten the electrical harness and its retainer clips from the cylinder head cover studs. 8. Disconnect the fuel line at the engine fuel rail. 9. Use compressed air to blow dirt and debris off the cylinder head cover. 10. Remove the cylinder head cover, ignition coils, bolts and studs as a complete assembly. CAUTION: Do not remove the coils from the cylinder head cover at this time to minimize dirt from entering the engine during disassembly. 11. On the bench, remove the four ignition coils from the cylinder head cover. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Technical Service Bulletins > Recalls for Camshaft: > F38 > Oct > 06 > Campaign Engine Camshaft Cap Bolt Torque > Page 1908 12. Inspect the rear of the # 1 camshaft bearing cap at the exhaust camshaft (Figure 1): If the split line of the bearings and the split line of the bearing cap-to-cylinder head are parallel to each other, continue with Step 13. If the split line of the bearings and the split line of the bearing cap-to-cylinder head are NOT parallel to each other, (the bearing has rotated) contact the STAR Center for further assistance. 13. Tighten each of the front camshaft bearing cap bolts to 20 ft.lbs. (27 N.m) in the following order (Figure 2): a. Exhaust side outside bolt (1). b. Intake side outside bolt (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Technical Service Bulletins > Recalls for Camshaft: > F38 > Oct > 06 > Campaign Engine Camshaft Cap Bolt Torque > Page 1909 c. Exhaust side middle bolt (3). d. Intake side middle bolt (4). 14. Clean all RTV from the cylinder head surface and wipe the surface with a clean cloth. 15. With a clean cloth, wipe the cylinder head cover gasket and inspect for damage (cuts, tears or voids). If damaged, replace with PN 04884765AA center gasket and/or PN 04884762AA perimeter gasket. 16. Apply a 1/8" (3mm) bead of Mopar Engine Sealant RTV to cylinder head/front cover T-joint (Figure 3). 17. Position the cylinder head cover on the engine and install cylinder head cover studs as shown. (Figure 4). 18. Position the cylinder head cover on the cylinder head and install all bolts. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Technical Service Bulletins > Recalls for Camshaft: > F38 > Oct > 06 > Campaign Engine Camshaft Cap Bolt Torque > Page 1910 19. Tighten the cylinder head cover fasteners in two steps following the sequence as shown in Figure 5: a. Tighten all fasteners to 44 in. lbs. (5 N.m). b. Tighten all bolts to 90 in. lbs. (10 N.m). 20. Install the four ignition coils. Tighten fasteners to 70 in. lbs. (8 N.m). 21. Connect the fuel line to the engine fuel rail. 22. Install the harness and its retainer clips onto the cylinder head cover studs. 23. Remove the plastic retainers (if any) from the engine cover and install the four retainers onto the appropriate studs of the cylinder head cover. 24. Connect the PCV and make-up air hoses to the cylinder head cover. 25. Install the engine cover. Check all four mounting grommets for proper engagement to the plastic retainers. 26. Connect the fuel pump harness connector to the fuel pump. 27. Install the fuel pump access cover and tighten the screw. 28. Install the rear seat lower cushion. 29. Connect the battery. 30. Install the air inlet duct over the battery. NOTE: Due to the fuel line pressure discharge procedure, a Diagnostic Trouble Code (DTC) may be set in some modules (PCM, TCV, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Connect the StarSCAN tool to the vehicle. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Technical Service Bulletins > Recalls for Camshaft: > F38 > Oct > 06 > Campaign Engine Camshaft Cap Bolt Torque > Page 1911 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque Technical Service Bulletin # F38 Date: 061001 Campaign - Engine Camshaft Cap Bolt Torque October 2006 Dealer Service Instructions for: Customer Satisfaction Notification F38 Engine Camshaft Cap Bolts Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) # 06-026 has been cancelled. Models 2007 (PM) Dodge Caliber 2007 (MK) Jeep(R) Compass NOTE: This notification applies only to the above vehicles with an engine build date code through TxxP11596 (Txx=traceability identifier [ignore], P1 = plant code, 159=Julian date for June 8, and, 6=2006). The date code is on the bar code label affixed to the front of the cylinder head cover. IMPORTANT: Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The engine camshaft cap bolts on about 250 of the above vehicles may not have been adequately tightened. This can cause damage to the camshaft bearing and/or the camshaft. Repair The # 1 engine exhaust camshaft bearing position must be inspected and the # 1 camshaft cap bolts must be tightened to specification. Parts Information IMPORTANT: Due to the likelihood that the required Mopar Engine Sealant RTV is already in your parts inventory, no Engine Sealant RTV will be distributed to involved dealers initially. Parts may be ordered as needed to support scheduled repairs. Each tube of sealant is sufficient to complete about 30 vehicles. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque > Page 1917 Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers should perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this notification only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure Engine Camshaft Cap Inspection and Bolt Tightening: 1. Discharge the fuel system pressure as follows: a. Remove the lower rear seat cushion. b. Remove the fuel pump module cover. c. Disconnect the electrical connector to the fuel pump module. d. Start and run engine until it stalls. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque > Page 1918 e. Attempt restarting engine until it will no longer run. f. Turn ignition key to OFF position. 2. Remove air inlet duct over the battery. 3. Disconnect the battery. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 4. Remove the engine cover and the plastic retainers on the valve cover studs. 5. Disconnect the electrical connectors on the ignition coils. 6. Disconnect the PCV and make-up air hoses from cylinder head cover. 7. Unfasten the electrical harness and its retainer clips from the cylinder head cover studs. 8. Disconnect the fuel line at the engine fuel rail. 9. Use compressed air to blow dirt and debris off the cylinder head cover. 10. Remove the cylinder head cover, ignition coils, bolts and studs as a complete assembly. CAUTION: Do not remove the coils from the cylinder head cover at this time to minimize dirt from entering the engine during disassembly. 11. On the bench, remove the four ignition coils from the cylinder head cover. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque > Page 1919 12. Inspect the rear of the # 1 camshaft bearing cap at the exhaust camshaft (Figure 1): If the split line of the bearings and the split line of the bearing cap-to-cylinder head are parallel to each other, continue with Step 13. If the split line of the bearings and the split line of the bearing cap-to-cylinder head are NOT parallel to each other, (the bearing has rotated) contact the STAR Center for further assistance. 13. Tighten each of the front camshaft bearing cap bolts to 20 ft.lbs. (27 N.m) in the following order (Figure 2): a. Exhaust side outside bolt (1). b. Intake side outside bolt (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque > Page 1920 c. Exhaust side middle bolt (3). d. Intake side middle bolt (4). 14. Clean all RTV from the cylinder head surface and wipe the surface with a clean cloth. 15. With a clean cloth, wipe the cylinder head cover gasket and inspect for damage (cuts, tears or voids). If damaged, replace with PN 04884765AA center gasket and/or PN 04884762AA perimeter gasket. 16. Apply a 1/8" (3mm) bead of Mopar Engine Sealant RTV to cylinder head/front cover T-joint (Figure 3). 17. Position the cylinder head cover on the engine and install cylinder head cover studs as shown. (Figure 4). 18. Position the cylinder head cover on the cylinder head and install all bolts. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque > Page 1921 19. Tighten the cylinder head cover fasteners in two steps following the sequence as shown in Figure 5: a. Tighten all fasteners to 44 in. lbs. (5 N.m). b. Tighten all bolts to 90 in. lbs. (10 N.m). 20. Install the four ignition coils. Tighten fasteners to 70 in. lbs. (8 N.m). 21. Connect the fuel line to the engine fuel rail. 22. Install the harness and its retainer clips onto the cylinder head cover studs. 23. Remove the plastic retainers (if any) from the engine cover and install the four retainers onto the appropriate studs of the cylinder head cover. 24. Connect the PCV and make-up air hoses to the cylinder head cover. 25. Install the engine cover. Check all four mounting grommets for proper engagement to the plastic retainers. 26. Connect the fuel pump harness connector to the fuel pump. 27. Install the fuel pump access cover and tighten the screw. 28. Install the rear seat lower cushion. 29. Connect the battery. 30. Install the air inlet duct over the battery. NOTE: Due to the fuel line pressure discharge procedure, a Diagnostic Trouble Code (DTC) may be set in some modules (PCM, TCV, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Connect the StarSCAN tool to the vehicle. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque > Page 1922 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Description and Operation > Camshaft - Description Camshaft: Description and Operation Camshaft - Description CAMSHAFTS Both camshafts have five bearing journal surfaces and two cam lobes per cylinder. The two front journals are larger to allow for feeding oil to the variable valve timing (VVT) camshaft phasers. Flanges on the third smaller journal control camshaft end play. At the rear of each camshaft is an integral cam sensor target. CAMSHAFT BEARING CAPS The front cam bearing cap spans both camshafts, and includes dowels for precise alignment. The front exhaust journal has a select fit bearing insert. This bearing is required to seal the oil passage to the camshaft phaser, because a portion of the lower bearing saddle is machined away for head bolt access. The select fit is required to minimize bearing clearance and oil leakage. An exhaust bearing grade (1, 2 or 3) is stamped into the front bearing cap adjacent to the exhaust cam journal. The bearings are also marked with the corresponding grade markings. If the bearing is replaced, the same grade must be used. Due to unique purpose of this bearing, it may appear to have uneven wear patterns. Unless the wear is excessive it is no cause for concern. The front intake journal has a full lower bearing saddle, and therefore, no bearing insert is required. All small bearing caps have a formed in arrow to assist in assembly. All small bearing cap arrows must point towards the center of the cylinder head. The small bearing caps are marked for position during the manufacturing process, and must be reinstalled in their original position. The #1 cap includes a passage to direct oil from the cylinder head oil gallery to the #1 small bearing journal. Through the #2 journal oil is fed into the camshaft as well. The hollow camshaft then distributes oil to the remainder of the small journals. The #3 small cap is machined at the front and rear face to control camshaft end-play. This cap has dowels for precise alignment. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Description and Operation > Camshaft - Description > Page 1925 Camshaft: Description and Operation Camshaft - Operation OPERATION The camshaft is driven by the crankshaft via drive sprockets and a chain. The camshaft has precisely machined lobes to provide accurate valve timing and duration. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures Camshaft: Procedures Measuring Camshaft End Play MEASURING CAMSHAFT END PLAY 1. Using a suitable tool, move camshaft as far rearward as it will go. 2. Zero dial indicator. 3. Move camshaft as far forward as it will go. 4. Record reading on dial indicator. For end play specification, Refer to ENGINE SPECIFICATIONS. 5. If end play is excessive, check cylinder head and camshaft for wear; replace as necessary. Camshaft - Cleaning CLEANING Clean camshafts with a suitable solvent. Camshaft - Inspection INSPECTION 1. Inspect camshaft bearing journals for damage. If journals are damaged, check the cylinder head for damage. Also check cylinder head oil holes for clogging. 2. Check the cam lobe and bearing surfaces for abnormal wear and damage. Replace camshaft if defective. NOTE: If camshaft is replaced due to lobe wear or damage, always replace the lash buckets. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1928 Camshaft: Removal and Replacement Camshaft - Removal REMOVAL 1. Remove engine cover by pulling upward. 2. Disconnect negative cable from battery (3). 3. Disconnect coil electrical connectors (1). 4. Remove cylinder head cover. 5. Raise vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1929 6. Remove right splash shield. 7. Rotate engine to TDC (1). 8. Make sure camshaft timing marks (3) are aligned. 9. Mark the chain link corresponding to timing marks (1) with a paint marker. 10. Remove timing tensioner plug (1) from front cover. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1930 11. Insert small allen wrench through timing tensioner plug hole and lift ratchet (2) upward to release the tensioner and push allen wrench inward. Leave the allen wrench installed during the remainder of this procedure. 12. Verify that camshaft timing marks (3) are facing each other as shown. 13. Mark the camshaft sprocket timing marks and the corresponding chain links (1) with a paint marker. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1931 14. Insert wedge 9701 (1) between camshaft phasers. 15. Lightly tap Wedge 9701 (2) into place until it will no longer sink down. 16. Remove the front camshaft bearing cap. 17. Slowly remove the remaining intake and exhaust camshaft bearing cap bolts one turn at a time. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1932 18. Remove intake camshaft (1) by lifting the rear of the camshaft upward. 19. Rotate the camshaft while lifting out of the front bearing cradle. 20. Lift the timing chain (2) off the sprocket (1). 21. Remove exhaust camshaft. 22. Secure timing chain with wire so that it does fall into the timing chain cover. Camshaft - Installation INSTALLATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1933 1. The cam cap (1) is numbered (2) either one, two, or three, this corresponds to the select fit bearing to use. 2. Install the corresponding select fit bearing (1). 3. Oil all of the camshaft journals with clean engine oil. 4. Install camshaft phasers on camshafts if removed. a. Install camshaft phaser making sure that the dowel is in the correct hole. b. Install camshaft phaser bolt and hand tighten. 5. Install timing chain onto exhaust cam sprocket making sure that the timing marks (1) on the sprocket and the painted chain link are aligned. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1934 6. Position exhaust camshaft and on bearing journals in the cylinder head. 7. Align exhaust cam timing mark (3) so it is parallel to the cylinder head as shown. 8. Install intake camshaft by raising the rear of the camshaft upward and roll the sprocket into the chain. 9. Align the timing marks (1) on the intake cam sprocket with the painted chain link. 10. Position the intake camshaft into the bearing journals in the cylinder head. 11. Verify that the timing marks (1) are aligned on both camshafts and that the timing marks (3) are parallel with the cylinder head. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1935 CAUTION: Install the front intake and exhaust camshaft bearing cap last. Ensure that the dowels are seated and follow torque sequence or damage to engine could result. NOTE: If the front camshaft bearing cap is broken, the cylinder head MUST be replaced. 12. Install intake and exhaust camshaft bearing caps and slowly tighten bolts to 12 Nm (105 in. lbs.) in the sequence shown. NOTE: Verify that the exhaust bearing shells are correctly installed, and the dowels are seated in the head, prior to torquing bolts. 13. Install the front intake and exhaust bearing cap and tighten bolts to 34 Nm (25 ft. lbs.) in the sequence shown. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1936 14. Verify that all timing marks (1, 3) are aligned. 15. Remove allen wrench from timing chain tensioner. 16. Remove locking wedge 9701 by pulling straight upward on pull rope. 17. Apply MOPAR(R) thread sealant to timing tensioner plug (1) and Install. 18. Install right splash shield. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1937 19. Install new cylinder head cover gaskets (1, 2). 20. Install cylinder head cover. 21. Install engine cover. 22. Connect negative battery cable. 23. Fill cooling system. 24. Fill with oil. 25. Start engine and check for leaks. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Testing and Inspection Lifter / Lash Adjuster: Testing and Inspection MECHANICAL VALVE TAPPET NOISE DIAGNOSIS A tappet-like noise may be produced from incorrect valve lash Refer to HYDRAULIC LIFTERS STANDARD PROCEDURE). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Procedures Lifter / Lash Adjuster: Procedures MEASURING VALVE LASH 1. Remove engine cover. 2. Remove cylinder head cover. 3. Rotate camshaft so lobes are vertical (1). 4. Check clearance using feeler gauges. 5. Repeat for all tappets and record readings. 6. If clearance was too small, go to the clearance to small procedure.Clearance to Small. 7. If clearance was too large, go to the clearance to large procedure.Clearance to Large. Clearance to Small Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Procedures > Page 1943 1. Remove camshafts. 2. Specification - clearance = change 3. Decrease bucket thickness by change figure. 4. Install camshafts. 5. Verify that valve lash is correct. Clearance to Large 1. Remove camshafts. 2. Clearance - specification = change. 3. Increase bucket thickness by change figure. 4. Install camshafts. 5. Verify that valve lash is correct. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Procedures > Page 1944 Lifter / Lash Adjuster: Removal and Replacement Removal REMOVAL NOTE: This procedure is for in-vehicle service with camshafts installed. NOTE: Camshaft tappets must be replaced if cylinder head or camshafts are replaced. 1. Remove cylinder head cover. 2. Remove camshafts. 3. Remove camshaft tappets (1). 4. Repeat removal procedure for each camshaft tappet (1). 5. If reusing, mark each camshaft bucket for reassembly in original position. Installation INSTALLATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Procedures > Page 1945 NOTE: If reinstalling original tappets they must go back in their original location or engine damage could result. 1. Apply a light coat of clean engine oil to camshafts tappets (1) prior to assembly. 2. Install camshaft tappets (1) into cylinder head. 3. Repeat installation procedure for each camshaft tappet. 4. Install camshafts. NOTE: If installing new tappets, the valve lash procedure must be performed. 5. Install cylinder head cover. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Connecting Rod Connecting Rod Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Service and Repair > Connecting Rod Bearing Fitting Connecting Rod Bearing: Service and Repair Connecting Rod Bearing Fitting CONNECTING ROD - FITTING There are three different sizes of rod bearings available. Connecting rod bearing identification (4) can be found on the nose of the crankshaft (3). Use the table below for proper bearing selection. Connecting Rod Bearing Selection 1. For measuring connecting rod bearing clearance procedure and use of Plastigage Refer to ENGINE STANDARD PROCEDURE. For bearing clearance refer to Engine Specifications. Refer to ENGINE SPECIFICATIONS). NOTE: The rod bolts should not be reused. 2. Before installing the NEW rod bolts the threads and under the bolt head should be oiled with clean engine oil. 3. Install each bolt finger tight then alternately torque each bolt to assemble the cap properly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Service and Repair > Connecting Rod Bearing Fitting > Page 1952 4. Tighten the connecting rod bolts using the 2 step torque-turn method. Tighten according to the following values: CAUTION: Do not use a torque wrench for the second step. - Tighten the bolts to 27 Nm (20 ft. lbs.). - Tighten the connecting rod bolts an additional 90°. 5. Using a feeler gauge, check connecting rod side clearance. Refer to clearance specifications Refer to ENGINE - SPECIFICATIONS. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Service and Repair > Connecting Rod Bearing Fitting > Page 1953 Connecting Rod Bearing: Service and Repair Measuring Bearing Clearance Using Plastigage MEASURING BEARING CLEARANCE USING PLASTIGAGE Engine crankshaft bearing clearances can be determined by use of Plastigage or equivalent. The following is the recommended procedure for the use of Plastigage: 1. Remove oil film from surface to be checked. Plastigage is soluble in oil. 2. Place a piece of Plastigage (1) across the entire width of the journal. (In addition, suspected areas can be checked by placing the Plastigage in the suspected area). Torque the bearing cap bolts of the bearing being checked to the proper specifications. 3. Remove the bearing cap and compare the width of the flattened Plastigage with the scale provided on the package. Locate the band closest to the same width. This band shows the amount of clearance. Differences in readings between the ends indicate the amount of taper present. Record all readings taken. Compare clearance measurements to specs found in engine specifications Refer to ENGINE SPECIFICATIONS. Plastigage generally is accompanied by two scales. One scale is in inches, the other is a metric scale. NOTE: Plastigage is available in a variety of clearance ranges. Use the most appropriate range for the specifications you are checking. 4. Install the proper crankshaft bearings to achieve the specified bearing clearances. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications Connecting Rod: Specifications Connecting Rod Bearing Cap Torque Connecting Rod Bearing Cap Step 1 .................................................................................................. ...................................................................................................... 25 Nm (18 ft. lbs.) Step 2 .............. .............................................................................................................................................................. ................................... additional 90° Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1957 Connecting Rod: Description and Operation DESCRIPTION The pistons are made of a cast aluminum alloy. The pistons have pressed-in pins attached to forged connecting rods. The pistons pin is offset 0.8 mm (0.0314 in.) towards the thrust side of the piston. The connecting rods are a cracked cap design and are not repairable. The piston with rings, connecting rod and piston pin are serviced as an assembly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Piston and Connecting Rod - Removal Connecting Rod: Service and Repair Piston and Connecting Rod - Removal REMOVAL NOTE: Pistons, rings, and rods are serviced as an assembly. CAUTION: To maintain engine balance, 1, 3, or 4 pistons can be replaced. If 2 pistons are replaced, engine will be out of balance. 1. Remove engine. 2. Separate engine from transaxle. 3. Remove engine from dolly 6135 (8) and place on a suitable engine stand. 4. Remove cylinder head. 5. Drain engine oil (2). 6. Remove oil pan (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Piston and Connecting Rod - Removal > Page 1960 7. Remove oil filter (1). 8. Remove balance shaft assembly. 9. Remove ladder frame. NOTE: Remove any carbon build up and clean debris from cylinder prior to piston removal to avoid scratching piston skirts. 10. Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. 11. Rotate crankshaft so that each connecting rod is centered in cylinder bore. 12. Using a permanent ink or paint marker, identify cylinder number on each connecting rod cap. CAUTION: DO NOT use a number stamp or a punch to mark connecting rods, as damage to connecting rod could occur. CAUTION: Care must be taken not to damage the fractured rod and cap joint surfaces, as engine damage many occur. 13. Remove connecting rod bolts and cap. NOTE: Do not reuse connecting rod bolts. 14. Carefully push each piston and rod assembly out of cylinder bore. Re-install bearing cap on the mating rod. 15. Repeat procedure for each piston and connecting rod assembly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Piston and Connecting Rod - Removal > Page 1961 Connecting Rod: Service and Repair Piston and Connecting Rod - Installation INSTALLATION 1. Install piston rings on piston. 2. Before installing pistons and connecting rod assemblies into the bore, be sure that top compression ring gap (1) and the second compression ring gap (3) are staggered so that neither is in line with oil ring rail gap. 3. Before installing the ring compressor, make sure the oil ring expander ends are butted (1) and the rail gaps (2, 4) located as shown above. As viewed from the top of the piston. 4. Immerse the piston head and rings in clean engine oil, slide the ring compressor, over the piston. Be sure position of rings does not change during this operation. 5. The directional arrow stamped on the piston should face toward the front of the engine. 6. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Lubricate connecting rod journal with clean engine oil. NOTE: There are three different size rod bearings, perform rod bearing selection procedure. NOTE: The rod bearing sizes are indicated on the nose of the crankshaft. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Piston and Connecting Rod - Removal > Page 1962 7. Install connecting rod upper bearing half into connecting rod. 8. Install ring compressor (3). 9. Tap the piston (1) down in cylinder bore, using a hammer handle (2). At the same time, guide connecting rod into position on connecting rod journal. NOTE: The connecting rod cap bolts should NOT be reused. 10. Before installing the NEW bolts, the threads should be coated with clean engine oil. 11. Install connecting rod lower bearing half into connecting rod cap. Install connecting rod cap. 12. Install each bolt finger tight then alternately torque each bolt to assemble the cap properly. 13. Tighten the connecting rod bolts using the 2 step torque-turn method. Tighten according to the following values: CAUTION: Do not use a torque wrench for the second step. - Tighten the bolts to 20 Nm (15 ft. lbs.). - Tighten the connecting rod bolts an additional 90°. 14. Using a feeler gauge, check connecting rod side clearance. 15. Install the ladder frame. 16. Install oil pump/Balance Shaft Carrier Assembly. 17. Install oil pan. 18. Install cylinder head. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Piston and Connecting Rod - Removal > Page 1963 19. Install engine on dolly. 20. Connect transaxle assembly to engine. 21. Install engine. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications Crankshaft Crankshaft Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 1967 Crankshaft Main Bearing Cap-Bolts ..................................................................................................................................... 27 Nm + 45° (20 ft. lbs.) + 45° Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair > Crankshaft Main Bearing Selection Crankshaft Main Bearing: Service and Repair Crankshaft Main Bearing Selection MAIN BEARING SELECTION NOTE: There are three different possibilities for the upper main bearings and five different lower main bearings. The upper and lower bearing shells are not interchangeable. The lower main bearing identification (2) is stamped in the nose of the crankshaft (3). There are 5 different bearing sizes available 0 through 4. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair > Crankshaft Main Bearing Selection > Page 1970 The upper main bearing shell identification (1) is located in the middle of cylinder block on the right side of the engine. There are three different size bearings available. The bearing class is read downward from top and corresponds to the front journal to the rear journal on the bottom. Upper Main Bearing Selection Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair > Crankshaft Main Bearing Selection > Page 1971 Crankshaft Main Bearing: Service and Repair Measuring Bearing Clearance Using Plastigage MEASURING BEARING CLEARANCE USING PLASTIGAGE Engine crankshaft bearing clearances can be determined by use of Plastigage or equivalent. The following is the recommended procedure for the use of Plastigage: 1. Remove oil film from surface to be checked. Plastigage is soluble in oil. 2. Place a piece of Plastigage (1) across the entire width of the journal. (In addition, suspected areas can be checked by placing the Plastigage in the suspected area). Torque the bearing cap bolts of the bearing being checked to the proper specifications. 3. Remove the bearing cap and compare the width of the flattened Plastigage with the scale provided on the package. Locate the band closest to the same width. This band shows the amount of clearance. Differences in readings between the ends indicate the amount of taper present. Record all readings taken. Compare clearance measurements to specs found in engine specifications Refer to ENGINE SPECIFICATIONS. Plastigage generally is accompanied by two scales. One scale is in inches, the other is a metric scale. NOTE: Plastigage is available in a variety of clearance ranges. Use the most appropriate range for the specifications you are checking. 4. Install the proper crankshaft bearings to achieve the specified bearing clearances. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications Crankshaft Crankshaft Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures Crankshaft: Procedures Crankshaft - Inspection INSPECTION The crankshaft main journals should be checked for excessive wear, taper and scoring. Limits of taper on any crankshaft main journals should be held to 0.006 mm (0.00024 in.). Limits of taper on any crankshaft rod journals should be held to 0.005 mm (0.0002 in.). DO NOT nick crank pin or bearing fillets. Limits of out of round on any crankshaft journals should be held to 0.005 mm (0.0002 in). DO NOT nick crank pin or bearing fillets. Measuring Crankshaft End Play MEASURING CRANKSHAFT END PLAY 1. Mount a dial indicator (2) to front of engine with the locating probe on nose of crankshaft (1). 2. Move crankshaft all the way to the rear of its travel. 3. Zero the dial indicator. 4. Move crankshaft all the way to the front and read the dial indicator. Refer to ENGINE SPECIFICATIONS for end play specification. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 1977 Crankshaft: Removal and Replacement Crankshaft - Removal REMOVAL NOTE: Crankshaft can not be removed when engine is in vehicle. 1. Remove engine assembly from vehicle. 2. Separate transaxle from engine. 3. Remove flex plate/flywheel (1). 4. Remove crankshaft rear oil seal. 5. Remove engine from cradle 6710 (11) and mount engine on a suitable repair stand. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 1978 6. Drain engine oil (2). 7. Remove oil filter (1). 8. Remove crankshaft vibration damper (2). 9. Remove water pump pulley (3). 10. Remove engine mount support bracket (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 1979 11. Remove the oil pan (2). 12. Remove timing chain cover. 13. Remove the timing chain. 14. Remove balance shaft module. 15. Remove the crankshaft sprocket (1). 16. Remove crankshaft position sensor retaining bolt (1) and remove sensor (2). 17. Remove ladder frame. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 1980 NOTE: If piston/connecting rod replacement is necessary, remove cylinder head. CAUTION: DO NOT use a number stamp or a punch to mark connecting rods. Damage to connecting rod could occur. 18. Using a permanent ink or paint marker, identify cylinder number on each connecting rod and cap. 19. Remove all connecting rod bolts and caps. Care should be taken not to damage the fracture rod and cap surfaces. NOTE: Do not reuse connecting rod bolts. 20. Remove main bearing caps. CAUTION: Use extreme care when handling crankshaft. Tone wheel damage can occur if crankshaft is mis-handled. 21. Lift out crankshaft from cylinder block. Do not damage the main bearings or journals when removing the crankshaft. Crankshaft - Installation INSTALLATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 1981 The crankshaft is supported in five main bearings. All upper bearing shells (2) in the crankcase have oil grooves and holes. All lower bearing shells (1) are smooth. Crankshaft end play is controlled by a two piece thrust bearing (3) on the number three main bearing journal. 1. Clean main bearing cap bolt holes with Mopar(R) brake parts cleaner or equivalent and blow out with compressed air. 2. Install the main bearing upper (2) shells with the lubrication groove and oil hole in the engine block. 3. Make certain oil holes in block line up with oil hole in bearings and bearing tabs seat in the block tab slots. NOTE: If the crankshaft is sent out for machine work, it must be balanced as an assembly with the target ring installed. 4. Clean crankshaft and target ring with MOPAR(R) Brake Parts cleaner and dry with compressed air to ensure that the crankshaft mating surface and target ring mounting holes are free from oil and lock patch debris. NOTE: Always use NEW mounting screws whether installing original or new target ring. 5. Install NEW mounting screws finger tight starting with the #1 location. Make sure engagement occurs with the shoulder of the screws and mounting hole before starting all other screws. 6. Tighten all mounting screws with T30 torx bit to 13 Nm (110 in-lbs) in the sequence shown. NOTE: Lightly apply trans gel to thrust bearings to hold bearings in block. NOTE: The thrust bearings must be installed the notches facing the crankshaft. 7. Install thrust bearings (2) in block (1). CAUTION: Do not get oil on the ladder frame mating surface. It will affect the ability of the RTV to seal the ladder frame to cylinder block. 8. Oil the bearings and journals. Install crankshaft in engine block. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 1982 9. Install lower main bearings (1) into main bearing cap. Make certain the bearing tabs are seated into the bearing cap slots. NOTE: Main bearing caps are stamped 1 - 5 front to rear. Arrows on the caps must point towards the front of the engine. 10. Install main bearing caps to engine block. 11. Before installing the bolts the threads should be clean and dry. 12. To ensure correct thrust bearing alignment, perform the following steps: - Step 1: Rotate crankshaft until number 4 piston is at TDC. - Step 2: Move crankshaft rearward to limits of travel. - Step 3: Then, move crankshaft forward to limits of travel. - Step 4: Wedge an appropriate tool between the rear of the cylinder block and the rear crankshaft counterweight. This will hold the crankshaft in its furthest forward position. 13. Tighten bolts (1 - 10) to 27 Nm + 45° (20 ft. lbs. + 45°) in the sequence shown above. 14. Remove wedge tool used to hold crankshaft. 15. Check the crankshaft turning torque, it should not exceed 5.6 Nm (50 in. lbs.). 16. Check crankshaft end play. 17. Install connecting rod bearings and caps. Do Not Reuse Connecting Rod Bolts. Tighten connecting rod bolts to 20 Nm + 90° (15 ft. lbs.) + 90°. 18. Install the ladder frame assembly. 19. Install the balance shaft module. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 1983 20. Install crankshaft position sensor (2) and tighten bolt (1). 21. Install cylinder head if it was removed. 22. Install front crankshaft sprocket (1). 23. Install the timing chain. 24. Install the timing chain front cover. 25. Install the oil pan. 26. Install rear crankshaft oil seal. 27. Install front crankshaft oil seal. 28. Install engine mount support bracket (1). 29. Install crankshaft vibration damper (2). 30. Install water pump pulley (3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 1984 31. Remove engine from repair stand and position on dolly 6135 (8) and engine support cradle 6710 (2, 11). Install safety straps (5, 9) around the engine to cradle and tighten and lock them into position. 32. Install crankshaft rear oil seal. 33. Install drive plate/flex plate using new bolts. Tighten bolts to 95 Nm (70 ft. lbs.). 34. Attach transaxle to engine. Tighten bellhousing bolts to 101 Nm (75 ft. lbs.). 35. Install the engine assembly. 36. Install new oil filter (1) and fill with oil. 37. Fill with coolant. 38. Start engine and check for leaks. 39. Install engine cover. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Engine Block Heater - Description Engine Block Heater: Description and Operation Engine Block Heater - Description DESCRIPTION The cartridge type block heater is mounted in a bore at the rear of the block under the coolant adapter. The block heater does not directly contact coolant. It heads the aluminum block. The heater is powered by 110 Volt AC through a power cord and connector. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Engine Block Heater - Description > Page 1989 Engine Block Heater: Description and Operation Engine Block Heater - Operation OPERATION The block heater element is inserted into a bore in the engine block. When electrical power (110 volt A.C.) is applied to the element, it creates heat. This heat is transferred to the aluminum engine block. This provides easier engine starting and faster warm-up when vehicle is operated in areas having extremely low temperatures. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Page 1990 Engine Block Heater: Testing and Inspection ENGINE BLOCK HEATER TESTING If unit does not operate, trouble can be in either the power cord or the heater element. Test power cord for continuity with a 110-volt voltmeter or 110-volt test light; test heater element continuity with an ohmmeter or 12-volt test light. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Engine Block Heater - Removal Engine Block Heater: Service and Repair Engine Block Heater - Removal REMOVAL 1. Remove engine cover. 2. Remove air cleaner inlet. 3. Detach power cord plug from heater. 4. Remove retaining clip (1). Remove block heater assembly (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Engine Block Heater - Removal > Page 1993 Engine Block Heater: Service and Repair Engine Block Heater - Installation INSTALLATION 1. Thoroughly clean bore hole. 2. Insert block heater assembly into bore. 3. Install retaining clip. 4. Connect power cord to block heater. 5. Install air intake inlet. 6. Install engine cover. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft Damper-Bolt ...................................................................................................................... ................................................. 210 Nm 155 (ft. lbs.) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Service and Repair > Vibration Damper - Removal Harmonic Balancer - Crankshaft Pulley: Service and Repair Vibration Damper - Removal REMOVAL 1. Remove accessory drive belts. 2. Install Damper holder 9707 (1). 3. Remove crankshaft damper bolt. 4. Pull damper off crankshaft. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Service and Repair > Vibration Damper - Removal > Page 1999 Harmonic Balancer - Crankshaft Pulley: Service and Repair Vibration Damper - Installation INSTALLATION 1. Install crankshaft damper. 2. Apply clean engine oil crankshaft damper bolt threads and between bolt head and washer. Tighten bolt to 210 Nm (155 ft. lbs.). 3. Install accessory drive belts. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Pistons Pistons Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 2003 Piston: Description and Operation DESCRIPTION The pistons are made of a cast aluminum alloy. The pistons have pressed-in pins attached to forged connecting rods. The pistons pin is offset 0.8 mm (0.0314 in.) towards the thrust side of the piston. The connecting rods are a cracked cap design and are not repairable. The piston with rings, connecting rod and piston pin are serviced as an assembly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures Piston: Procedures Piston and Bore Measurement PISTON and BORE MEASUREMENT NOTE: Pistons and cylinder bores should be measured at normal room temperature, 21° C (70° F). Piston and cylinder wall must be clean and dry. Piston diameter should be measured 90 degrees to piston pin (1). 1. Measurement should be taken approximately 17 mm (0.669 in.) from the bottom of the skirt (2) as shown. NOTE: Correct piston to bore clearance must be established in order to assure quiet and economical operation. 2. Cylinder bores should be measured halfway down the cylinder bore and transverse (measurement location B) to the engine crankshaft center line shown. Refer to for Engine Specifications. Piston Selection STANDARD PROCEDURE - PISTON SELECTION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 2006 The pistons are select fit to each bore. There are three different grades of pistons available; A, B, and C. The piston identification (2) is located in the middle of the block on the right side of the engine. The bore identification starts at the top and reads downward. Bore #1 is at the top and bore #4 is at the bottom. The piston, rings and rod are serviced as an assembly, after determining what size piston is needed, refer to Refer to CONNECTING ROD BEARINGS - STANDARD PROCEDURE to determine correct rod bearing size. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 2007 Piston: Removal and Replacement Piston and Connecting Rod - Removal REMOVAL NOTE: Pistons, rings, and rods are serviced as an assembly. CAUTION: To maintain engine balance, 1, 3, or 4 pistons can be replaced. If 2 pistons are replaced, engine will be out of balance. 1. Remove engine. 2. Separate engine from transaxle. 3. Remove engine from dolly 6135 (8) and place on a suitable engine stand. 4. Remove cylinder head. 5. Drain engine oil (2). 6. Remove oil pan (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 2008 7. Remove oil filter (1). 8. Remove balance shaft assembly. 9. Remove ladder frame. NOTE: Remove any carbon build up and clean debris from cylinder prior to piston removal to avoid scratching piston skirts. 10. Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. 11. Rotate crankshaft so that each connecting rod is centered in cylinder bore. 12. Using a permanent ink or paint marker, identify cylinder number on each connecting rod cap. CAUTION: DO NOT use a number stamp or a punch to mark connecting rods, as damage to connecting rod could occur. CAUTION: Care must be taken not to damage the fractured rod and cap joint surfaces, as engine damage many occur. 13. Remove connecting rod bolts and cap. NOTE: Do not reuse connecting rod bolts. 14. Carefully push each piston and rod assembly out of cylinder bore. Re-install bearing cap on the mating rod. 15. Repeat procedure for each piston and connecting rod assembly. Piston and Connecting Rod - Installation INSTALLATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 2009 1. Install piston rings on piston. 2. Before installing pistons and connecting rod assemblies into the bore, be sure that top compression ring gap (1) and the second compression ring gap (3) are staggered so that neither is in line with oil ring rail gap. 3. Before installing the ring compressor, make sure the oil ring expander ends are butted (1) and the rail gaps (2, 4) located as shown above. As viewed from the top of the piston. 4. Immerse the piston head and rings in clean engine oil, slide the ring compressor, over the piston. Be sure position of rings does not change during this operation. 5. The directional arrow stamped on the piston should face toward the front of the engine. 6. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Lubricate connecting rod journal with clean engine oil. NOTE: There are three different size rod bearings, perform rod bearing selection procedure. NOTE: The rod bearing sizes are indicated on the nose of the crankshaft. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 2010 7. Install connecting rod upper bearing half into connecting rod. 8. Install ring compressor (3). 9. Tap the piston (1) down in cylinder bore, using a hammer handle (2). At the same time, guide connecting rod into position on connecting rod journal. NOTE: The connecting rod cap bolts should NOT be reused. 10. Before installing the NEW bolts, the threads should be coated with clean engine oil. 11. Install connecting rod lower bearing half into connecting rod cap. Install connecting rod cap. 12. Install each bolt finger tight then alternately torque each bolt to assemble the cap properly. 13. Tighten the connecting rod bolts using the 2 step torque-turn method. Tighten according to the following values: CAUTION: Do not use a torque wrench for the second step. - Tighten the bolts to 20 Nm (15 ft. lbs.). - Tighten the connecting rod bolts an additional 90°. 14. Using a feeler gauge, check connecting rod side clearance. 15. Install the ladder frame. 16. Install oil pump/Balance Shaft Carrier Assembly. 17. Install oil pan. 18. Install cylinder head. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 2011 19. Install engine on dolly. 20. Connect transaxle assembly to engine. 21. Install engine. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Piston Rings Piston Rings Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Service and Repair > Procedures Piston Ring: Procedures PISTON RING - FITTING 1. Wipe cylinder bore clean. Insert ring and push down with piston to ensure it is square in bore. The ring gap measurement must be made with the ring positioning at least 13 mm (0.50 inch) from bottom of cylinder bore and below the bottom of the oil ring travel where cylinder bore has minimal wear. Check gap with feeler gauge. Refer to Engine Specifications. NOTE: Ring end gap measurements are sensitive to the ring being square in the bore. Care must be used to avoid tilting the rings in cylinder bores when taking measurements. 2. Check piston ring to groove side clearance. Refer to Engine Specifications. CAUTION: Exercise care when using tools on piston. Do not scratch or gouge piston surface or ring grooves as this may cause engine damage. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Service and Repair > Procedures > Page 2017 Piston Ring: Removal and Replacement Piston Ring(s) - Removal REMOVAL 1. Using a suitable ring expander, remove upper and intermediate piston rings. 2. Remove the upper oil ring side rail, lower oil ring side rail and then oil ring expander from piston. 3. Clean ring grooves of any carbon deposits. Piston Ring(s) - Installation INSTALLATION NOTE: The identification mark on face of upper and intermediate piston rings must point toward top of piston. CAUTION: Install piston rings in the following order: - Oil ring expander. - Upper oil ring side rail. - Lower oil ring side rail. - No. 2 Intermediate piston ring. - No. 1 Upper piston ring. 1. Install oil ring expander. 2. Install upper side rail first and then the lower side rail. Install the side rails by placing one end between the piston ring groove and the oil ring expander. Hold end firmly and press down the portion to be installed until side rail is in position. Do not use a piston ring expander. NOTE: The compression rings are marked Y1 for the upper compression ring and Y2 for the second compression ring. These markings must face upward. 3. Install No. 2 piston ring and then No. 1 piston ring. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Service and Repair > Procedures > Page 2018 NOTE: Install the piston rings so the gaps positioned as indicated with the piston viewed from the top. NOTE: Staggering ring gap is important for oil control. 4. Install the oil expander so the ring gap is located in the (1) position. 5. Install the oil ring rails so the ring gap is located in the (2, 4) position. 6. Install the second compression ring so the ring gap is located in the (3) position. 7. Install the top compression so the ring gap is located in the (1) position. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Valve Lash Intake ................................................................................................................................................... .............................. 17 - 23 mm (0.006 - 0.009 in.) Exhaust ................................................................ .............................................................................................................. 27 - 33 mm (0.010 - 0.012 in.) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications > Page 2023 Valve Clearance: Adjustments MEASURING VALVE LASH 1. Remove engine cover. 2. Remove cylinder head cover. 3. Rotate camshaft so lobes are vertical (1). 4. Check clearance using feeler gauges. 5. Repeat for all tappets and record readings. 6. If clearance was too small, go to the clearance to small procedure.Clearance to Small. 7. If clearance was too large, go to the clearance to large procedure.Clearance to Large. Clearance to Small Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications > Page 2024 1. Remove camshafts. 2. Specification - clearance = change 3. Decrease bucket thickness by change figure. 4. Install camshafts. 5. Verify that valve lash is correct. Clearance to Large 1. Remove camshafts. 2. Clearance - specification = change. 3. Increase bucket thickness by change figure. 4. Install camshafts. 5. Verify that valve lash is correct. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE PROCEDURE 1. Remove lower rear seat cushion. 2. Remove the fuel pump module cover. 3. Disconnect the electrical connector for fuel pump module. 4. Start and run engine until it stalls. 5. Attempt restarting engine until it will no longer run. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Page 2028 6. Turn ignition key to OFF position. 7. Disconnect negative battery cable. 8. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory. The scan tool must be used to erase a DTC. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Camshaft Housing > Component Information > Technical Service Bulletins > Recalls: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque Technical Service Bulletin # F38 Date: 061001 Campaign - Engine Camshaft Cap Bolt Torque October 2006 Dealer Service Instructions for: Customer Satisfaction Notification F38 Engine Camshaft Cap Bolts Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) # 06-026 has been cancelled. Models 2007 (PM) Dodge Caliber 2007 (MK) Jeep(R) Compass NOTE: This notification applies only to the above vehicles with an engine build date code through TxxP11596 (Txx=traceability identifier [ignore], P1 = plant code, 159=Julian date for June 8, and, 6=2006). The date code is on the bar code label affixed to the front of the cylinder head cover. IMPORTANT: Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The engine camshaft cap bolts on about 250 of the above vehicles may not have been adequately tightened. This can cause damage to the camshaft bearing and/or the camshaft. Repair The # 1 engine exhaust camshaft bearing position must be inspected and the # 1 camshaft cap bolts must be tightened to specification. Parts Information IMPORTANT: Due to the likelihood that the required Mopar Engine Sealant RTV is already in your parts inventory, no Engine Sealant RTV will be distributed to involved dealers initially. Parts may be ordered as needed to support scheduled repairs. Each tube of sealant is sufficient to complete about 30 vehicles. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Camshaft Housing > Component Information > Technical Service Bulletins > Recalls: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque > Page 2037 Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers should perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this notification only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure Engine Camshaft Cap Inspection and Bolt Tightening: 1. Discharge the fuel system pressure as follows: a. Remove the lower rear seat cushion. b. Remove the fuel pump module cover. c. Disconnect the electrical connector to the fuel pump module. d. Start and run engine until it stalls. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Camshaft Housing > Component Information > Technical Service Bulletins > Recalls: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque > Page 2038 e. Attempt restarting engine until it will no longer run. f. Turn ignition key to OFF position. 2. Remove air inlet duct over the battery. 3. Disconnect the battery. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 4. Remove the engine cover and the plastic retainers on the valve cover studs. 5. Disconnect the electrical connectors on the ignition coils. 6. Disconnect the PCV and make-up air hoses from cylinder head cover. 7. Unfasten the electrical harness and its retainer clips from the cylinder head cover studs. 8. Disconnect the fuel line at the engine fuel rail. 9. Use compressed air to blow dirt and debris off the cylinder head cover. 10. Remove the cylinder head cover, ignition coils, bolts and studs as a complete assembly. CAUTION: Do not remove the coils from the cylinder head cover at this time to minimize dirt from entering the engine during disassembly. 11. On the bench, remove the four ignition coils from the cylinder head cover. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Camshaft Housing > Component Information > Technical Service Bulletins > Recalls: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque > Page 2039 12. Inspect the rear of the # 1 camshaft bearing cap at the exhaust camshaft (Figure 1): If the split line of the bearings and the split line of the bearing cap-to-cylinder head are parallel to each other, continue with Step 13. If the split line of the bearings and the split line of the bearing cap-to-cylinder head are NOT parallel to each other, (the bearing has rotated) contact the STAR Center for further assistance. 13. Tighten each of the front camshaft bearing cap bolts to 20 ft.lbs. (27 N.m) in the following order (Figure 2): a. Exhaust side outside bolt (1). b. Intake side outside bolt (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Camshaft Housing > Component Information > Technical Service Bulletins > Recalls: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque > Page 2040 c. Exhaust side middle bolt (3). d. Intake side middle bolt (4). 14. Clean all RTV from the cylinder head surface and wipe the surface with a clean cloth. 15. With a clean cloth, wipe the cylinder head cover gasket and inspect for damage (cuts, tears or voids). If damaged, replace with PN 04884765AA center gasket and/or PN 04884762AA perimeter gasket. 16. Apply a 1/8" (3mm) bead of Mopar Engine Sealant RTV to cylinder head/front cover T-joint (Figure 3). 17. Position the cylinder head cover on the engine and install cylinder head cover studs as shown. (Figure 4). 18. Position the cylinder head cover on the cylinder head and install all bolts. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Camshaft Housing > Component Information > Technical Service Bulletins > Recalls: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque > Page 2041 19. Tighten the cylinder head cover fasteners in two steps following the sequence as shown in Figure 5: a. Tighten all fasteners to 44 in. lbs. (5 N.m). b. Tighten all bolts to 90 in. lbs. (10 N.m). 20. Install the four ignition coils. Tighten fasteners to 70 in. lbs. (8 N.m). 21. Connect the fuel line to the engine fuel rail. 22. Install the harness and its retainer clips onto the cylinder head cover studs. 23. Remove the plastic retainers (if any) from the engine cover and install the four retainers onto the appropriate studs of the cylinder head cover. 24. Connect the PCV and make-up air hoses to the cylinder head cover. 25. Install the engine cover. Check all four mounting grommets for proper engagement to the plastic retainers. 26. Connect the fuel pump harness connector to the fuel pump. 27. Install the fuel pump access cover and tighten the screw. 28. Install the rear seat lower cushion. 29. Connect the battery. 30. Install the air inlet duct over the battery. NOTE: Due to the fuel line pressure discharge procedure, a Diagnostic Trouble Code (DTC) may be set in some modules (PCM, TCV, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Connect the StarSCAN tool to the vehicle. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Camshaft Housing > Component Information > Technical Service Bulletins > Recalls: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque > Page 2042 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Camshaft Housing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 23-008-08 > Feb > 08 > Interior - Seat Track Creak/Squeak Sound Seat Track: All Technical Service Bulletins Interior - Seat Track Creak/Squeak Sound NUMBER: 23-008-08 GROUP: Body DATE: February 15, 2008 SUBJECT: Seat Track Creak/Squeak Sound OVERVIEW: This bulletin involves inspecting the seat track for metal to metal contact. The stationary track may have a rolled in rear corner causing interference. If this corner is contacting movable track, track adjustment is necessary. MODELS: 2007 - 2008 (JS41) Sebring/Avenger 2007 - 2008 (PM) Caliber 2007 - 2008 (MK) Compass/Patriot NOTE: This bulletin applies to models built before December 7, 2007 (MDH1207XX). SYMPTOM/CONDITION: Some vehicle occupants may experience a creak or squeak sound while driving with seat stationary and occupied. DIAGNOSIS: If the customer experiences the Symptom/Condition, inspect the seat track: 1. Move the affected seat to the full rear position. 2. Inspect the movable portion of the inner seat track lip for metal to metal contact (witness mark) with the stationary portion at the rear edge. Is there a witness mark indicating metal to metal contact between stationary and movable seat track? (Fig. 1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Camshaft Housing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 23-008-08 > Feb > 08 > Interior - Seat Track Creak/Squeak Sound > Page 2048 a. No >>> This bulletin does not apply, further diagnosis is required. b. Yes >>> Perform the Repair Procedure. SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Move the affected seat to the full forward position. 2. Insert flat blade screwdriver or small pry bar between movable and stationary seat track at rear edge of track (Fig. 2). NOTE: Care should be taken not to over-adjust the track lip as this will cause interference on the other side of the upper track rail. CAUTION: Only slight adjustment is necessary. Pry lip of seat track just enough to achieve 0.5mm (0.020 In) of clearance. 3. Carefully pry the stationary rail lip toward the center of the seat by prying with screwdriver toward the outside of the seat track providing additional rail to rail clearance of 0.5mm (0.020 In) (Fig. 2). 4. Move the seat to the full rear position and verify clearance between rails. 5. Repeat for other affected seat track(s) as necessary. POLICY: Reimbursable within the provisions of the warranty. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Camshaft Housing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 23-008-08 > Feb > 08 > Interior - Seat Track Creak/Squeak Sound > Page 2049 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Camshaft Housing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 23-028-06A > Sep > 06 > Interior - Front Seat Cushion Loose/Clicks/Creaks Seat Track: All Technical Service Bulletins Interior - Front Seat Cushion Loose/Clicks/Creaks NUMBER: 23-028-06 REV. A GROUP: Body DATE: September 20, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-028-06, DATED JULY 19, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES AN UPDATED OVERVIEW, VEHICLE BUILD DATE AND REPAIR PROCEDURE. SUBJECT: Clicking/Creaking Sound From Seat Or Looseness At Front Of Seat Cushion OVERVIEW: This bulletin involves adding electrical tape to the cushion pan attachment crosstube, installing new plastic brackets on the driver, passenger or both front seat(s) **and removing the pink foam block from both the lower front outboard side shields**. MODELS: 2007 (PM) Caliber 2007 (MK-49) Compass NOTE: **This bulletin applies to vehicles built before September 16, 2006 (MDH 0916XX).** SYMPTOM/CONDITION: The front cushion of the seat may feel loose and/or the seats may make a clicking or creaking sound when: i. Stopping and accelerating ii. Driving around corners DIAGNOSIS: If the sound is present for the driver or passenger front seats as described in the Symptom/Condition perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Camshaft Housing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 23-028-06A > Sep > 06 > Interior - Front Seat Cushion Loose/Clicks/Creaks > Page 2054 2. Move the seat to the forward position. 3. From under the seat remove the bolts (2) and the straps (1). 4. Disconnect the electrical connector, if equipped. 5. Is tape already present on the crosstube? a. Yes - Proceed to Step # 7. b. No - Proceed to Step # 6. 6. Apply electrical tape per (Fig. 2). Wrap the tape around the crosstube, two wraps. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Camshaft Housing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 23-028-06A > Sep > 06 > Interior - Front Seat Cushion Loose/Clicks/Creaks > Page 2055 7. Install new plastic brackets. NOTE: Each front seat has two brackets. 8. Reinstall metal straps and bolts, torque to 12.5Nm (110 in. lbs.) 9. **Is the vehicle a Compass built before September 16, 2006?** a. Yes - Proceed to Step # 10. b. No - Repair Complete. CAUTION: Do not pull side shield out too much in the next step. Only pull out enough to access the pink foam block. 10. **Using your hand pull the lower outboard side shield away from the seat frame (Fig. 3).** 11. **Remove the pink foam block from the lower outboard side shield.** 12. **Ensure the lower outboard side shield is snapped back into place.** NOTE: Be sure to perform this action for both front seats. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Camshaft Housing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 23-028-06A > Sep > 06 > Interior - Front Seat Cushion Loose/Clicks/Creaks > Page 2056 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Camshaft Housing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 23-024-06 > Jun > 06 > Interior - Front Seat Track Squeal/Click/Scraping Noises Seat Track: All Technical Service Bulletins Interior - Front Seat Track Squeal/Click/Scraping Noises NUMBER: 23-024-06 GROUP: Body DATE: June 1, 2006 SUBJECT: Scraping, Clicking Or Squeal Sound From Seat Track OVERVIEW: This bulletin involves applying white lithium grease to the seat tracks for both front seats. MODELS: 2007 (PM) Caliber NOTE: This bulletin applies to vehicles built on or before March 6, 2006 (MDH 0306XX). SYMPTOM/CONDITION: The seats may make a squeal, clicking or scraping sound when: i. Stopping and accelerating ii. Driving around corners iii. Adjusting the seat This may be more noticeable at colder ambient temperatures. DIAGNOSIS: If the sound is present as described in the symptoms listed above perform the Repair Procedure. PARTS REQUIRED: NOTE: Do not use aerosol spray white lithium grease. This grease is not thick enough. NOTE: One tube of grease can treat more than 10 vehicles. REPAIR PROCEDURE: 1. Open door. 2. Slide seat to full back position. 3. Lubricate the seat track (p/n 68003883AA) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Camshaft Housing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 23-024-06 > Jun > 06 > Interior - Front Seat Track Squeal/Click/Scraping Noises > Page 2061 a. Squeeze a dab of grease the size of a nickel between the driver side right outboard lower rail and the right outboard upper rail of the seat track (Fig. 1). b. Squeeze a dab of grease the size of a nickel between the driver side left outboard lower rail and the left outboard upper rail of the seat track (Fig. 1). 4. Move the seat back and forth a few times to distribute the grease along the track. 5. Repeat steps 4 and 5 for the passenger seat. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Camshaft Housing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Housing: > 23-008-08 > Feb > 08 > Recalls for Camshaft Housing: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque Technical Service Bulletin # F38 Date: 061001 Campaign - Engine Camshaft Cap Bolt Torque October 2006 Dealer Service Instructions for: Customer Satisfaction Notification F38 Engine Camshaft Cap Bolts Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) # 06-026 has been cancelled. Models 2007 (PM) Dodge Caliber 2007 (MK) Jeep(R) Compass NOTE: This notification applies only to the above vehicles with an engine build date code through TxxP11596 (Txx=traceability identifier [ignore], P1 = plant code, 159=Julian date for June 8, and, 6=2006). The date code is on the bar code label affixed to the front of the cylinder head cover. IMPORTANT: Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The engine camshaft cap bolts on about 250 of the above vehicles may not have been adequately tightened. This can cause damage to the camshaft bearing and/or the camshaft. Repair The # 1 engine exhaust camshaft bearing position must be inspected and the # 1 camshaft cap bolts must be tightened to specification. Parts Information IMPORTANT: Due to the likelihood that the required Mopar Engine Sealant RTV is already in your parts inventory, no Engine Sealant RTV will be distributed to involved dealers initially. Parts may be ordered as needed to support scheduled repairs. Each tube of sealant is sufficient to complete about 30 vehicles. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Camshaft Housing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Housing: > 23-008-08 > Feb > 08 > Recalls for Camshaft Housing: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque > Page 2071 Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers should perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this notification only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure Engine Camshaft Cap Inspection and Bolt Tightening: 1. Discharge the fuel system pressure as follows: a. Remove the lower rear seat cushion. b. Remove the fuel pump module cover. c. Disconnect the electrical connector to the fuel pump module. d. Start and run engine until it stalls. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Camshaft Housing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Housing: > 23-008-08 > Feb > 08 > Recalls for Camshaft Housing: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque > Page 2072 e. Attempt restarting engine until it will no longer run. f. Turn ignition key to OFF position. 2. Remove air inlet duct over the battery. 3. Disconnect the battery. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 4. Remove the engine cover and the plastic retainers on the valve cover studs. 5. Disconnect the electrical connectors on the ignition coils. 6. Disconnect the PCV and make-up air hoses from cylinder head cover. 7. Unfasten the electrical harness and its retainer clips from the cylinder head cover studs. 8. Disconnect the fuel line at the engine fuel rail. 9. Use compressed air to blow dirt and debris off the cylinder head cover. 10. Remove the cylinder head cover, ignition coils, bolts and studs as a complete assembly. CAUTION: Do not remove the coils from the cylinder head cover at this time to minimize dirt from entering the engine during disassembly. 11. On the bench, remove the four ignition coils from the cylinder head cover. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Camshaft Housing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Housing: > 23-008-08 > Feb > 08 > Recalls for Camshaft Housing: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque > Page 2073 12. Inspect the rear of the # 1 camshaft bearing cap at the exhaust camshaft (Figure 1): If the split line of the bearings and the split line of the bearing cap-to-cylinder head are parallel to each other, continue with Step 13. If the split line of the bearings and the split line of the bearing cap-to-cylinder head are NOT parallel to each other, (the bearing has rotated) contact the STAR Center for further assistance. 13. Tighten each of the front camshaft bearing cap bolts to 20 ft.lbs. (27 N.m) in the following order (Figure 2): a. Exhaust side outside bolt (1). b. Intake side outside bolt (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Camshaft Housing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Housing: > 23-008-08 > Feb > 08 > Recalls for Camshaft Housing: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque > Page 2074 c. Exhaust side middle bolt (3). d. Intake side middle bolt (4). 14. Clean all RTV from the cylinder head surface and wipe the surface with a clean cloth. 15. With a clean cloth, wipe the cylinder head cover gasket and inspect for damage (cuts, tears or voids). If damaged, replace with PN 04884765AA center gasket and/or PN 04884762AA perimeter gasket. 16. Apply a 1/8" (3mm) bead of Mopar Engine Sealant RTV to cylinder head/front cover T-joint (Figure 3). 17. Position the cylinder head cover on the engine and install cylinder head cover studs as shown. (Figure 4). 18. Position the cylinder head cover on the cylinder head and install all bolts. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Camshaft Housing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Housing: > 23-008-08 > Feb > 08 > Recalls for Camshaft Housing: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque > Page 2075 19. Tighten the cylinder head cover fasteners in two steps following the sequence as shown in Figure 5: a. Tighten all fasteners to 44 in. lbs. (5 N.m). b. Tighten all bolts to 90 in. lbs. (10 N.m). 20. Install the four ignition coils. Tighten fasteners to 70 in. lbs. (8 N.m). 21. Connect the fuel line to the engine fuel rail. 22. Install the harness and its retainer clips onto the cylinder head cover studs. 23. Remove the plastic retainers (if any) from the engine cover and install the four retainers onto the appropriate studs of the cylinder head cover. 24. Connect the PCV and make-up air hoses to the cylinder head cover. 25. Install the engine cover. Check all four mounting grommets for proper engagement to the plastic retainers. 26. Connect the fuel pump harness connector to the fuel pump. 27. Install the fuel pump access cover and tighten the screw. 28. Install the rear seat lower cushion. 29. Connect the battery. 30. Install the air inlet duct over the battery. NOTE: Due to the fuel line pressure discharge procedure, a Diagnostic Trouble Code (DTC) may be set in some modules (PCM, TCV, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Connect the StarSCAN tool to the vehicle. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Camshaft Housing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Housing: > 23-008-08 > Feb > 08 > Recalls for Camshaft Housing: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque > Page 2076 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Camshaft Housing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Housing: > 23-028-06A > Sep > 06 > Component Information > Technical Service Bulletins > Recalls for Camshaft Housing: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque Technical Service Bulletin # F38 Date: 061001 Campaign - Engine Camshaft Cap Bolt Torque October 2006 Dealer Service Instructions for: Customer Satisfaction Notification F38 Engine Camshaft Cap Bolts Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) # 06-026 has been cancelled. Models 2007 (PM) Dodge Caliber 2007 (MK) Jeep(R) Compass NOTE: This notification applies only to the above vehicles with an engine build date code through TxxP11596 (Txx=traceability identifier [ignore], P1 = plant code, 159=Julian date for June 8, and, 6=2006). The date code is on the bar code label affixed to the front of the cylinder head cover. IMPORTANT: Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The engine camshaft cap bolts on about 250 of the above vehicles may not have been adequately tightened. This can cause damage to the camshaft bearing and/or the camshaft. Repair The # 1 engine exhaust camshaft bearing position must be inspected and the # 1 camshaft cap bolts must be tightened to specification. Parts Information IMPORTANT: Due to the likelihood that the required Mopar Engine Sealant RTV is already in your parts inventory, no Engine Sealant RTV will be distributed to involved dealers initially. Parts may be ordered as needed to support scheduled repairs. Each tube of sealant is sufficient to complete about 30 vehicles. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Camshaft Housing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Housing: > 23-028-06A > Sep > 06 > Component Information > Technical Service Bulletins > Recalls for Camshaft Housing: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque > Page 2087 Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers should perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this notification only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure Engine Camshaft Cap Inspection and Bolt Tightening: 1. Discharge the fuel system pressure as follows: a. Remove the lower rear seat cushion. b. Remove the fuel pump module cover. c. Disconnect the electrical connector to the fuel pump module. d. Start and run engine until it stalls. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Camshaft Housing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Housing: > 23-028-06A > Sep > 06 > Component Information > Technical Service Bulletins > Recalls for Camshaft Housing: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque > Page 2088 e. Attempt restarting engine until it will no longer run. f. Turn ignition key to OFF position. 2. Remove air inlet duct over the battery. 3. Disconnect the battery. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 4. Remove the engine cover and the plastic retainers on the valve cover studs. 5. Disconnect the electrical connectors on the ignition coils. 6. Disconnect the PCV and make-up air hoses from cylinder head cover. 7. Unfasten the electrical harness and its retainer clips from the cylinder head cover studs. 8. Disconnect the fuel line at the engine fuel rail. 9. Use compressed air to blow dirt and debris off the cylinder head cover. 10. Remove the cylinder head cover, ignition coils, bolts and studs as a complete assembly. CAUTION: Do not remove the coils from the cylinder head cover at this time to minimize dirt from entering the engine during disassembly. 11. On the bench, remove the four ignition coils from the cylinder head cover. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Camshaft Housing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Housing: > 23-028-06A > Sep > 06 > Component Information > Technical Service Bulletins > Recalls for Camshaft Housing: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque > Page 2089 12. Inspect the rear of the # 1 camshaft bearing cap at the exhaust camshaft (Figure 1): If the split line of the bearings and the split line of the bearing cap-to-cylinder head are parallel to each other, continue with Step 13. If the split line of the bearings and the split line of the bearing cap-to-cylinder head are NOT parallel to each other, (the bearing has rotated) contact the STAR Center for further assistance. 13. Tighten each of the front camshaft bearing cap bolts to 20 ft.lbs. (27 N.m) in the following order (Figure 2): a. Exhaust side outside bolt (1). b. Intake side outside bolt (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Camshaft Housing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Housing: > 23-028-06A > Sep > 06 > Component Information > Technical Service Bulletins > Recalls for Camshaft Housing: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque > Page 2090 c. Exhaust side middle bolt (3). d. Intake side middle bolt (4). 14. Clean all RTV from the cylinder head surface and wipe the surface with a clean cloth. 15. With a clean cloth, wipe the cylinder head cover gasket and inspect for damage (cuts, tears or voids). If damaged, replace with PN 04884765AA center gasket and/or PN 04884762AA perimeter gasket. 16. Apply a 1/8" (3mm) bead of Mopar Engine Sealant RTV to cylinder head/front cover T-joint (Figure 3). 17. Position the cylinder head cover on the engine and install cylinder head cover studs as shown. (Figure 4). 18. Position the cylinder head cover on the cylinder head and install all bolts. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Camshaft Housing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Housing: > 23-028-06A > Sep > 06 > Component Information > Technical Service Bulletins > Recalls for Camshaft Housing: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque > Page 2091 19. Tighten the cylinder head cover fasteners in two steps following the sequence as shown in Figure 5: a. Tighten all fasteners to 44 in. lbs. (5 N.m). b. Tighten all bolts to 90 in. lbs. (10 N.m). 20. Install the four ignition coils. Tighten fasteners to 70 in. lbs. (8 N.m). 21. Connect the fuel line to the engine fuel rail. 22. Install the harness and its retainer clips onto the cylinder head cover studs. 23. Remove the plastic retainers (if any) from the engine cover and install the four retainers onto the appropriate studs of the cylinder head cover. 24. Connect the PCV and make-up air hoses to the cylinder head cover. 25. Install the engine cover. Check all four mounting grommets for proper engagement to the plastic retainers. 26. Connect the fuel pump harness connector to the fuel pump. 27. Install the fuel pump access cover and tighten the screw. 28. Install the rear seat lower cushion. 29. Connect the battery. 30. Install the air inlet duct over the battery. NOTE: Due to the fuel line pressure discharge procedure, a Diagnostic Trouble Code (DTC) may be set in some modules (PCM, TCV, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Connect the StarSCAN tool to the vehicle. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Camshaft Housing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Housing: > 23-028-06A > Sep > 06 > Component Information > Technical Service Bulletins > Recalls for Camshaft Housing: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque > Page 2092 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Camshaft Housing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Housing: > 23-028-06A > Sep > 06 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Housing: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque Technical Service Bulletin # F38 Date: 061001 Campaign - Engine Camshaft Cap Bolt Torque October 2006 Dealer Service Instructions for: Customer Satisfaction Notification F38 Engine Camshaft Cap Bolts Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) # 06-026 has been cancelled. Models 2007 (PM) Dodge Caliber 2007 (MK) Jeep(R) Compass NOTE: This notification applies only to the above vehicles with an engine build date code through TxxP11596 (Txx=traceability identifier [ignore], P1 = plant code, 159=Julian date for June 8, and, 6=2006). The date code is on the bar code label affixed to the front of the cylinder head cover. IMPORTANT: Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The engine camshaft cap bolts on about 250 of the above vehicles may not have been adequately tightened. This can cause damage to the camshaft bearing and/or the camshaft. Repair The # 1 engine exhaust camshaft bearing position must be inspected and the # 1 camshaft cap bolts must be tightened to specification. Parts Information IMPORTANT: Due to the likelihood that the required Mopar Engine Sealant RTV is already in your parts inventory, no Engine Sealant RTV will be distributed to involved dealers initially. Parts may be ordered as needed to support scheduled repairs. Each tube of sealant is sufficient to complete about 30 vehicles. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Camshaft Housing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Housing: > 23-028-06A > Sep > 06 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Housing: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque > Page 2098 Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers should perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this notification only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure Engine Camshaft Cap Inspection and Bolt Tightening: 1. Discharge the fuel system pressure as follows: a. Remove the lower rear seat cushion. b. Remove the fuel pump module cover. c. Disconnect the electrical connector to the fuel pump module. d. Start and run engine until it stalls. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Camshaft Housing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Housing: > 23-028-06A > Sep > 06 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Housing: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque > Page 2099 e. Attempt restarting engine until it will no longer run. f. Turn ignition key to OFF position. 2. Remove air inlet duct over the battery. 3. Disconnect the battery. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 4. Remove the engine cover and the plastic retainers on the valve cover studs. 5. Disconnect the electrical connectors on the ignition coils. 6. Disconnect the PCV and make-up air hoses from cylinder head cover. 7. Unfasten the electrical harness and its retainer clips from the cylinder head cover studs. 8. Disconnect the fuel line at the engine fuel rail. 9. Use compressed air to blow dirt and debris off the cylinder head cover. 10. Remove the cylinder head cover, ignition coils, bolts and studs as a complete assembly. CAUTION: Do not remove the coils from the cylinder head cover at this time to minimize dirt from entering the engine during disassembly. 11. On the bench, remove the four ignition coils from the cylinder head cover. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Camshaft Housing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Housing: > 23-028-06A > Sep > 06 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Housing: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque > Page 2100 12. Inspect the rear of the # 1 camshaft bearing cap at the exhaust camshaft (Figure 1): If the split line of the bearings and the split line of the bearing cap-to-cylinder head are parallel to each other, continue with Step 13. If the split line of the bearings and the split line of the bearing cap-to-cylinder head are NOT parallel to each other, (the bearing has rotated) contact the STAR Center for further assistance. 13. Tighten each of the front camshaft bearing cap bolts to 20 ft.lbs. (27 N.m) in the following order (Figure 2): a. Exhaust side outside bolt (1). b. Intake side outside bolt (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Camshaft Housing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Housing: > 23-028-06A > Sep > 06 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Housing: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque > Page 2101 c. Exhaust side middle bolt (3). d. Intake side middle bolt (4). 14. Clean all RTV from the cylinder head surface and wipe the surface with a clean cloth. 15. With a clean cloth, wipe the cylinder head cover gasket and inspect for damage (cuts, tears or voids). If damaged, replace with PN 04884765AA center gasket and/or PN 04884762AA perimeter gasket. 16. Apply a 1/8" (3mm) bead of Mopar Engine Sealant RTV to cylinder head/front cover T-joint (Figure 3). 17. Position the cylinder head cover on the engine and install cylinder head cover studs as shown. (Figure 4). 18. Position the cylinder head cover on the cylinder head and install all bolts. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Camshaft Housing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Housing: > 23-028-06A > Sep > 06 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Housing: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque > Page 2102 19. Tighten the cylinder head cover fasteners in two steps following the sequence as shown in Figure 5: a. Tighten all fasteners to 44 in. lbs. (5 N.m). b. Tighten all bolts to 90 in. lbs. (10 N.m). 20. Install the four ignition coils. Tighten fasteners to 70 in. lbs. (8 N.m). 21. Connect the fuel line to the engine fuel rail. 22. Install the harness and its retainer clips onto the cylinder head cover studs. 23. Remove the plastic retainers (if any) from the engine cover and install the four retainers onto the appropriate studs of the cylinder head cover. 24. Connect the PCV and make-up air hoses to the cylinder head cover. 25. Install the engine cover. Check all four mounting grommets for proper engagement to the plastic retainers. 26. Connect the fuel pump harness connector to the fuel pump. 27. Install the fuel pump access cover and tighten the screw. 28. Install the rear seat lower cushion. 29. Connect the battery. 30. Install the air inlet duct over the battery. NOTE: Due to the fuel line pressure discharge procedure, a Diagnostic Trouble Code (DTC) may be set in some modules (PCM, TCV, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Connect the StarSCAN tool to the vehicle. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Camshaft Housing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Housing: > 23-028-06A > Sep > 06 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Housing: > F38 > Oct > 06 > Campaign - Engine Camshaft Cap Bolt Torque > Page 2103 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Camshaft Housing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Housing: > 23-024-06 > Jun > 06 > Component Information > Locations Timing Component Alignment Marks: Locations ^ Verify that the crankshaft sprocket keyway is at the 9 o'clock position. ^ Align camshaft timing marks (3) so they are parallel to the cylinder head and aligned each other as shown. ^ Install timing chain so plated links on chain align with timing marks on camshaft sprockets (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Camshaft Housing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Housing: > 23-024-06 > Jun > 06 > Component Information > Locations > Page 2109 ^ Align timing mark on the crankshaft sprocket (2) with the plated link (3) on the timing chain. Position chain so slack will be on the tensioner side. ^ Rotate the crankshaft CLOCKWISE two complete revolutions until the crankshaft is repositioned at the TDC position with the key way at the 9 o'clock position. ^ Verify that the camshafts timing marks (3) are in the proper position. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Camshaft Housing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Housing: > 23-024-06 > Jun > 06 > Component Information > Locations > Page 2110 ^ Install the balancer and verify that balancer mark (2) and cover mark (1) are aligned. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Removal Valve Cover: Service and Repair Removal REMOVAL 1. Remove engine cover. 2. Disconnect ignition coil electrical connectors. 3. Disconnect PCV and make-up air hoses from cylinder head cover. 4. Use compressed air to blow dirt and debris off the cylinder head cover prior to removal. 5. Remove cylinder head cover bolts. 6. Remove cylinder head cover from cylinder head. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Removal > Page 2115 Valve Cover: Service and Repair Installation INSTALLATION 1. Install new cylinder head cover gaskets (1, 2). 2. Install studs in cover as shown. 3. Clean all RTV from cylinder head. NOTE: When using RTV, the sealing surfaces must be clean and free from grease and oil. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Removal > Page 2116 NOTE: When using RTV, parts should be assembled in 10 minutes and tighten to final torque within 45 minutes. 4. Apply a dot of Mopar(R) engine sealant RTV or equivalent to cylinder head/front cover T-joint (1). 5. Install cylinder head cover assembly to cylinder head and install all bolts, ensuring the studs are located as shown. 6. Tighten bolts in sequence shown using a 2 step torque method as follows: a. Tighten all bolts to 5 Nm (44 in. lbs.) b. Tighten all bolts to 10 Nm (90 in. lbs.). 7. Install ignition coils. Tighten fasteners to 8 Nm (70 in. lbs.). 8. If the PCV valve was removed, tighten PCV valve to 5 Nm (44 in. lbs.). 9. Connect PCV and make-up air hoses to cylinder head cover. 10. Install engine cover. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Procedures Valve Spring: Procedures Cylinder Head On INSPECTION 1. Whenever valves have been removed for inspection, reconditioning or replacement, valve springs should be tested for correct load. Discard the springs that do not meet specifications. The following specifications apply to both intake and exhaust valves springs: - Valve closed nominal load - 75 lbs. @ 38.0 mm (1.50 in.) - Valve open nominal load - 134 lbs. @ 29.75 mm (1.17 in.) 2. Inspect each valve spring for squareness with a steel square and surface plate, test springs from both ends. If the spring is more than 1.5 mm (1/16 inch) out of square, install a new spring. Cylinder Head Off INSPECTION 1. Whenever valves have been removed for inspection, reconditioning or replacement, valve springs should be tested for correct load. Discard the springs that do not meet specifications. The following specifications apply to both intake and exhaust valves springs: - Valve closed nominal load - 75 lbs. @ 38.0 mm (1.50 in.) - Valve open nominal load - 134 lbs. @ 29.75 mm (1.17 in.) 2. Inspect each valve spring for squareness with a steel square and surface plate, test springs from both ends. If the spring is more than 1.5 mm (1/16 inch) out of square, install a new spring. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Procedures > Page 2121 Valve Spring: Removal and Replacement Removal CYLINDER HEAD ON 1. Rotate crankshaft until piston is at TDC on compression. 2. Remove cylinder head cover. 3. Remove camshafts. 4. Mark valve tappet location for assembly. 5. Remove valve tappets. 6. With air hose attached to adapter tool installed in spark plug hole, apply 90-120 psi air pressure. CAUTION: Care must be taken not to damage the tappet bore or engine damage may result. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Procedures > Page 2122 7. Using metric valve keeper tool (1) such as Snap-on(R) GA317 (or equivalent), and remove valve spring keepers and retainer. 8. Remove valve spring(s). 9. Remove valve stem seal(s) by a using valve stem seal tool. Installation CYLINDER HEAD ON CAUTION: Care must be taken not to damage the tappet bore or engine damage may result. 1. Install valve seal/valve spring seat (3) assembly. Push the assembly down with appropriate size socket to seat it onto the valve guide. 2. Install valve spring (2) and retainer (4) with keepers (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Procedures > Page 2123 3. Place the valve keepers in the retainer. Using metric valve keeper tool such as Snap-on(R) GA317 (or equivalent) installer (2) and remover (1) as a handle, install valve keepers with a downward push. 4. Remove air hose and install spark plugs. 5. Install valve tappets. 6. Install camshafts. 7. Install cylinder head cover. Removal CYLINDER HEAD OFF 1. With cylinder head removed from cylinder block, place a ball of rags in the combustion chamber. CAUTION: Care must be taken not to damage the tappet bore or engine damage may result. 2. Mark valve tappet location for assembly. 3. Remove valve tappets. 4. Using metric valve keeper tool such as Snap-on(R) GA317 (or equivalent) remover (1), remove valve keepers with a downward push. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Procedures > Page 2124 5. Remove retainer and springs. 6. Before removing valves, remove any burrs from valve stem lock grooves to prevent damage to the valve guides. Identify valves, locks and retainers to insure installation in original location. 7. Inspect the valves. Installation CYLINDER HEAD OFF CAUTION: Care must be taken not to damage the tappet bore or engine damage may result. 1. Coat valve stems with clean engine oil and insert in cylinder head. 2. Install new valve stem seals (3) on all valves using an appropriate sized socket to seat the seal/spring seat. The valve stem seals should be pushed firmly and squarely over valve guide. 3. Install valve springs (2). 4. Install keepers in retainer and place on valve spring. 5. Using metric valve keeper tool such as Snap-on(R) GA317 (or equivalent) installer (2) and remover (1) as a handle, push downward to install keepers. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Procedures > Page 2125 6. Check the valve spring installed height B after refacing the valve and seat. Make sure measurements are taken from top of spring seat to the bottom surface of spring retainer. If height is greater than 38.75 mm (1.525 in.), install a 0.762 mm (0.030 in.) spacer under the valve spring seat to bring spring height back within specification. 7. Install valve tappets. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Description and Operation > Description Valve: Description and Operation Description DESCRIPTION The valves are made of heat resistant steel. They have nitrided stems to prevent scuffing. Viton rubber valve stem seals are integral with the spring seats. The valves have a single bead lock keepers to retain the springs. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Description and Operation > Description > Page 2130 Valve: Description and Operation Operation OPERATION The four valves per cylinder (two intake and two exhaust) are opened by using direct acting tappets which are actuated by the camshaft. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Description and Operation > Page 2131 Valve: Service and Repair CLEANING Clean all valves thoroughly and discard burned, warped and cracked valves. CAUTION: Due to the small margin on the valves, grinding is not recommended. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams Drive Belt: Diagrams Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 2136 Drive Belt: Description and Operation GAS ENGINE The accessory drive belt (2) is a serpentine type belt that is driven by the crankshaft pulley (6). The belt drives the A/C compressor, generator (3), power steering pump (1) and water pump (7). Belt tension is maintained by an automatic belt tensioner (8). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 2137 Drive Belt: Testing and Inspection ACCESSORY DRIVE BELT VISUAL DIAGNOSIS When diagnosing serpentine accessory drive belts, small cracks that run across the ribbed surface of the belt from rib to rib (1), are considered normal. These are not a reason to replace the belt. However, cracks running along a rib (not across) (2) are not normal. Any belt with cracks running along a rib must be replaced. Also replace the belt if it has excessive wear, frayed cords or severe glazing. Refer to ACCESSORY DRIVE BELT DIAGNOSIS CHART for further belt diagnosis. NOISE DIAGNOSIS Noises generated by the accessory drive belt are most noticeable at idle. Before replacing a belt to resolve a noise condition, inspect all of the accessory drive pulleys for contamination, alignment, glazing, or excessive end play. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 2138 Accessory Drive Belt Diagnosis Chart (Part 1) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 2139 Accessory Drive Belt Diagnosis Chart (Part 2) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Procedures Drive Belt: Procedures CLEANING Clean all foreign debris from belt pulley grooves. The belt pulleys must be free of oil, grease, and coolants before installing the drive belt. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Procedures > Page 2142 Drive Belt: Removal and Replacement Removal GAS ENGINE 1. Using a wrench, rotate accessory drive belt tensioner (8) counterclockwise until accessory drive belt (2) can be removed from pulleys (5 and 9). 2. Remove accessory drive belt (2). Installation GAS ENGINE NOTE: When installing drive belt on the pulleys, make sure that belt is properly routed and all V-grooves make proper contact with pulley grooves. 1. Install the accessory drive belt (2) around all the pulleys except for the generator pulley (3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Procedures > Page 2143 2. Using a wrench, rotate accessory drive belt tensioner (8) counterclockwise until accessory drive belt (2) can be installed on the generator pulley (3). Release spring tension onto accessory drive belt (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Description and Operation Drive Belt Tensioner: Description and Operation DESCRIPTION The automatic belt tensioner maintains proper tension on the accessory drive belt. The tensioner pulley can be serviced separately. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Service and Repair > Removal Drive Belt Tensioner: Service and Repair Removal GAS ENGINE 1. Raise vehicle on hoist. 2. Remove belt splash shield (3). 3. Remove accessory drive belt. 4. Remove accessory drive belt tensioner mounting bolt. Remove accessory drive belt tensioner (8). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Service and Repair > Removal > Page 2149 Drive Belt Tensioner: Service and Repair Installation GAS ENGINE 1. Position accessory drive belt tensioner (8) and install mounting bolt (1). Tighten bolt (1) to 24 Nm (212 in. lbs.). 2. Install accessory drive belt. 3. Install belt splash shield (3). 4. Lower vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Description and Operation > Description Engine Mount: Description and Operation Description DESCRIPTION The engine mounting system consists of a four-point system utilizing two load-carrying mounts and two torque controlling mounts. The load-carrying mounts are located on each frame rail. The right and left mounts are hydro-elastic mounts. The two torque controlling mounts are attached to a fore/aft member and the front and rear of the engine. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Description and Operation > Description > Page 2154 Engine Mount: Description and Operation Operation OPERATION The four-point engine mounting system minimizes the transmission of structure-borne engine noise to the passenger compartment. The load-carrying right and left mounts dampen and isolate vertical motion and vibration. The front and rear mount absorb torque reaction forces and torsional vibrations. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount Engine Mount: Service and Repair Front Mount Removal REMOVAL 1. Raise vehicle. 2. Remove fore aft member (3) to mount (4) bolts. 3. Remove mount through bolt (1). 4. Remove fore aft member (3) mounting bolts and remove. 5. Remove front mount (4). Installation INSTALLATION 1. Position mount (4) and torque bolts to 47 Nm (35 ft. lbs.). 2. Install fore aft member (3) and torque bolts to 100 Nm (74 ft. lbs.). 3. Install mount through bolt (1) and torque to 47 Nm (35 ft. lbs.). 4. Lower vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 2157 Engine Mount: Service and Repair Left Mount Removal REMOVAL 1. Remove air cleaner inlet (2) and air cleaner housing (1). 2. Remove PCM (1). 3. Remove PCM mounting bracket. 4. Disconnect negative cable from battery (3). 5. Support transaxle with a suitable jack. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 2158 6. Remove left mount through bolt (3). 7. Remove left mount bracket to body frame rail fasteners (1). 8. Remove mount. Installation INSTALLATION 1. Position mount (2) in place. 2. Install left mount to frame rail bolts (1) and torque to 75 Nm (55 ft. lbs.). 3. Install mount through bolt (3) and torque to 100 Nm (74 ft.lbs.). 4. Remove jack. 5. Install PCM mounting bracket. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 2159 6. Install PCM (1). 7. Connect negative cable to battery (3). 8. Install air cleaner housing (1) and air cleaner inlet (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 2160 Engine Mount: Service and Repair Right Mount Removal REMOVAL 1. Remove coolant reservoir (3) and set aside. 2. Remove power steering reservoir (2) and set aside. 3. Remove windshield washer bottle (1). 4. Remove power steering line support bracket (1) from engine mount. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 2161 5. Support transaxle with a block of wood and a suitable jack. 6. Remove engine mount through bolt (4). 7. Remove engine mount bracket bolts (3). 8. Remove engine mount retaining bolts. 9. Remove engine mount. Installation INSTALLATION 1. Position right engine mount (1). 2. Install engine mount retaining bolts and tighten to 75 Nm (55 ft. lbs.). 3. Install engine mount adapter (2) and tighten bolts (3) to 68 Nm (50 ft. lbs.). 4. Install engine mount through bolt (4) and tighten to 88 Nm (65 ft. lbs.). 5. Remove jack. 6. Install power steering line support bracket (1) at engine mount. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 2162 7. Install windshield washer bottle (1). 8. Install power steering reservoir (2). 9. Install coolant reservoir (3). 10. Install engine cover. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 2163 Engine Mount: Service and Repair Rear Mount Removal REMOVAL 1. Remove rear mount retaining bolts (4). 2. Remove rear mount through bolt (1). 3. Remove oxygen sensor connector (2) from mount. 4. Remove rear mount (3). Installation INSTALLATION 1. Position rear mount (3). 2. Install rear mount retaining bolts (4) and torque to 50 Nm (37 ft. lbs.). 3. Install rear mount through bolt (1) and torque to 75 Nm (55 ft. lbs.). 4. Install oxygen sensor connector (2) retainer to mount (3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Service and Repair > Removal Idler Pulley: Service and Repair Removal REMOVAL 1. Raise vehicle on hoist. 2. Remove belt splash shield. 3. Remove accessory drive belt. 4. Remove idler pulley mounting bolt. Remove idler pulley (5 or 9). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Service and Repair > Removal > Page 2168 Idler Pulley: Service and Repair Installation INSTALLATION 1. Position pulley (5 or 9) in mounting position. Install idler pulley mounting bolt. Tighten bolt to 48 Nm (35 ft. lbs.). 2. Install accessory drive belt. 3. Install belt splash shield. 4. Lower vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure Oil Pressure Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Testing and Inspection > Checking Engine Oil Pressure Engine Oil Pressure: Testing and Inspection Checking Engine Oil Pressure CHECKING ENGINE OIL PRESSURE NOTE: Anytime the oil temperature sensor is removed, it should be replaced with a new sensor. 1. Disconnect and remove oil temperature sensor (1). CAUTION: Threads in cylinder head are British Standard Pipe (BSP). Do not install a NPT threaded adapter, this could crack the cylinder head. 2. Install threaded adapter 9879 (1). 3. Install oil pressure gauge (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Testing and Inspection > Checking Engine Oil Pressure > Page 2175 4. Start engine and record reading on oil pressure gauge (1). CAUTION: If oil pressure is 0 at idle, do not perform the 3000 RPM test 5. If oil pressure is 0 at idle, shut off engine. Check for pressure relief valve stuck open, a clogged oil pick-up screen. 6. Remove oil pan and inspect for debris. 7. Remove oil pressure relief valve. 8. Inspect oil pressure relief valve if damaged replace. 9. If pressure relief valve is ok, replace balance shaft module assembly. 10. After test is complete, remove oil pressure gauge (2) and adapter 9879 (1). 11. Install a new oil pressure temperature sensor (1) and connect electrical connector. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Testing and Inspection > Checking Engine Oil Pressure > Page 2176 Engine Oil Pressure: Testing and Inspection Checking VVT Oil Pressure CHECKING VVT OIL PRESSURE This test can be used to help diagnose VVT faults. 1. Disconnect and remove oil pressure sensor (1). CAUTION: Threads in block are 1/8"-28 British Standard Pipe (BSP). Do not install a National Pipe Thread (NPT) threaded adapter, this could crack the cylinder block. 2. Install an 1/8-28 BSP male to 1/8-27 female threaded adapter (2). 3. Install oil pressure gauge (1). 4. Start engine and record oil pressure. CAUTION: If oil pressure is 0 at idle, do not perform the 3000 RPM test 5. If oil pressure is 0 at idle, shut off engine. check for pressure relief valve stuck open, a clogged oil pick-up screen. 6. Remove oil pan and inspect for debris. 7. Remove oil pressure relief valve and inspect, if damaged replace pressure relief valve. 8. If pressure relief valve is ok, replace balance shaft module assembly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Testing and Inspection > Checking Engine Oil Pressure > Page 2177 9. After test is complete, remove test gauge (1) and fitting (2). 10. Install oil pressure sensor and electrical connector. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Engine Oil: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2182 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil and Oil Filter Capacity .......................................................................................................................................................... 4.5 Qt (4.26 Liters) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 2185 Engine Oil: Fluid Type Specifications Engine Oil Type ................................................................................................................................... ............................................................... SAE 5W-20 Use API certified engine oil. Refer to engine oil filler cap for correct SAE grade meeting Daimler Chrysler Material Standard MS-6395. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 2186 Engine Oil: Testing and Inspection ENGINE OIL LEVEL CHECK NOTE: The engine must be HOT when checking oil level. The best time to check engine oil level is after the engine is at operating temperature. Allow the engine to be shut off for at least 5 minutes before checking oil level. Checking the oil while the vehicle is on level ground will improve the accuracy of the oil level reading. Remove dipstick (1), and observe oil level. Add oil only when the level is at or below the SAFE mark. If the oil level is in the safe (2) range, do not add oil. CAUTION: Do not operate engine if the oil level is above the MAX mark on the dipstick. Excessive oil volume can cause oil aeration which can lead to engine failure due to loss of oil pressure or increase in oil temperature. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 2187 Engine Oil: Service and Repair ENGINE OIL AND FILTER CHANGE WARNING: New or used engine oil can be irritating to the skin. Avoid prolonged or repeated skin contact with engine oil. Contaminants in used engine oil, caused by internal combustion, can be hazardous to your health. Thoroughly wash exposed skin with soap and water. Do not wash skin with gasoline, diesel fuel, thinner, or solvents, health problems can result. Do not pollute, dispose of used engine oil properly. Contact your dealer or government agency for location of collection center in your area. Change engine oil at mileage and time intervals described in the Maintenance Schedule. 1. Run engine until achieving normal operating temperature. 2. Position the vehicle on a level surface and turn engine off. 3. Remove oil fill cap. 4. Raise vehicle on hoist. 5. Place a suitable oil collecting container under oil pan drain plug (2). 6. Remove oil pan drain plug (2) or and allow oil to drain into collecting container. Inspect drain plug threads for stretching or other damage. Replace drain plug and gasket if damaged. 7. Remove oil filter (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 2188 8. Install oil pan drain plug (2) and tighten drain plug to 28 Nm (20 ft. lbs.). 9. Install new oil filter (1). 10. Lower vehicle and fill crankcase with specified type and amount of engine oil. 11. Install oil fill cap. 12. Start engine and inspect for leaks. 13. Stop engine and inspect oil level. OIL FILTER SPECIFICATION All engines are equipped with a high quality full-flow, disposable type oil filter. Replace oil filter with a Mopar(R) or the equivalent. USED ENGINE OIL DISPOSAL Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to the WARNING listed above. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Description and Operation Oil Cooler: Description and Operation DESCRIPTION An engine oil cooler is used on some engine packages. The cooler is a coolant-to-oil type and mounted between the oil filter and oil filter adapter. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Removal Oil Cooler: Service and Repair Removal REMOVAL NOTE: The oil cooler can not be cleaned out. In the event that the engine requires rebuilding or replacement, the oil cooler should be replaced. 1. Raise vehicle on hoist. 2. Drain cooling system. 3. Disconnect oil cooler coolant hoses. 4. Remove oil filter (3). 5. Remove oil cooler connector bolt (2). 6. Remove oil cooler (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Removal > Page 2194 Oil Cooler: Service and Repair Installation INSTALLATION 1. Replace oil cooler seal (1). 2. Lubricate seal and position oil cooler to oil filter adapter, aligning notch to tab. 3. Install oil cooler connector bolt (2). Tighten connector bolt to 55 Nm (41 ft. lbs.). 4. Install oil filter (3). 5. Connect oil cooler coolant hose. 6. Lower vehicle. 7. Fill cooling system. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Service and Repair > Engine Oil and Filter Change Oil Filter: Service and Repair Engine Oil and Filter Change ENGINE OIL AND FILTER CHANGE WARNING: New or used engine oil can be irritating to the skin. Avoid prolonged or repeated skin contact with engine oil. Contaminants in used engine oil, caused by internal combustion, can be hazardous to your health. Thoroughly wash exposed skin with soap and water. Do not wash skin with gasoline, diesel fuel, thinner, or solvents, health problems can result. Do not pollute, dispose of used engine oil properly. Contact your dealer or government agency for location of collection center in your area. Change engine oil at mileage and time intervals described in the Maintenance Schedule. 1. Run engine until achieving normal operating temperature. 2. Position the vehicle on a level surface and turn engine off. 3. Remove oil fill cap. 4. Raise vehicle on hoist. 5. Place a suitable oil collecting container under oil pan drain plug (2). 6. Remove oil pan drain plug (2) or and allow oil to drain into collecting container. Inspect drain plug threads for stretching or other damage. Replace drain plug and gasket if damaged. 7. Remove oil filter (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Service and Repair > Engine Oil and Filter Change > Page 2199 8. Install oil pan drain plug (2) and tighten drain plug to 28 Nm (20 ft. lbs.). 9. Install new oil filter (1). 10. Lower vehicle and fill crankcase with specified type and amount of engine oil. 11. Install oil fill cap. 12. Start engine and inspect for leaks. 13. Stop engine and inspect oil level. OIL FILTER SPECIFICATION All engines are equipped with a high quality full-flow, disposable type oil filter. Replace oil filter with a Mopar(R) or the equivalent. USED ENGINE OIL DISPOSAL Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to the WARNING listed above. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Service and Repair > Engine Oil and Filter Change > Page 2200 Oil Filter: Service and Repair Removal REMOVAL CAUTION: When servicing the oil filter, avoid deforming the filter can by installing the remove/install tool band strap against the can to base lock seam. The lock seam joining the can to the base is reinforced by the base plate. 1. Using a suitable filter wrench, turn oil filter (1) counterclockwise to remove. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Service and Repair > Engine Oil and Filter Change > Page 2201 Oil Filter: Service and Repair Installation INSTALLATION 1. Clean and check filter mounting surface. The surface must be smooth, flat and free of debris or pieces of gasket. 2. Lubricate new oil filter gasket. 3. Screw oil filter (1) on until the gasket contacts base. Tighten to 14 Nm (11 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Line, Turbocharger > Component Information > Service and Repair > Removal - Lines And Hoses Oil Line: Service and Repair Removal - Lines And Hoses REMOVAL - LINES AND HOSES OIL SUPPLY LINE 1. Raise vehicle on hoist. 2. Remove elbow support bracket. 3. Disconnect oil supply line flared fitting from brass fitting at engine block. 4. Lower vehicle. 5. Disconnect oil supply line flared fitting from brass fitting at turbocharger. 6. Remove oil supply line. OIL RETURN LINE Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Line, Turbocharger > Component Information > Service and Repair > Removal - Lines And Hoses > Page 2206 1. Raise vehicle on hoist. 2. Remove the two fasteners securing the oil return line to the turbocharger. 3. Remove hose clamp from oil return line. 4. Remove oil return line from crankcase nipple. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Line, Turbocharger > Component Information > Service and Repair > Removal - Lines And Hoses > Page 2207 Oil Line: Service and Repair Installation INSTALLATION OIL SUPPLY LINE 1. If brass fitting was removed from engine block or turbocharger, apply thread sealer to threads and install. Tighten brass fitting to 41 Nm (30 ft. lbs.). 2. Position oil supply line to mounting location. 3. Hand start flared fitting at turbocharger. 4. Raise vehicle on hoist. 5. Hand start flared fitting at engine block. 6. Tighten flared fittings to 31 Nm (23 ft. lbs.). 7. Install elbow support bracket. 8. Lower vehicle. OIL RETURN LINE 1. Clean gasket surfaces. 2. Install new gasket. 3. Install oil return line hose over crankcase nipple. 4. Install the two fasteners securing the oil return line to the turbocharger. Tighten fasteners to 12 Nm (105 in. lbs.). 5. Install hose clamp for oil return line hose. 6. Lower vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Oil Pan-Bolts M6 Bolts ............................................................................................................................................... ............................................. 12 Nm (105 in. lbs.) M8 Bolts ................................................................ ............................................................................................................................... 24 Nm (18 ft. lbs.) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Removal Oil Pan: Service and Repair Removal REMOVAL 1. Raise vehicle on hoist. 2. Remove oil drain plug (2) and drain the engine oil. 3. Remove accessory drive belt splash shield. 4. Remove lower A/C compressor mounting bolt (if equipped). 5. Remove A/C mounting bracket (2). NOTE: Do not use pry points in block to remove oil pan. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Removal > Page 2213 6. Remove oil pan retaining bolts. 7. Using a putty knife (1), loosen seal around oil pan (2). 8. Remove oil pan (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Removal > Page 2214 Oil Pan: Service and Repair Installation INSTALLATION NOTE: Oil pan sealing surfaces must be free of grease or oil. NOTE: Parts must be assembled within 10 minutes of applying RTV. 1. Apply Mopar(R) Engine RTV GEN II at the front cover to engine block parting lines (1). 2. Apply a 2 mm bead of Mopar(R) Engine RTV GEN II around the oil pan as shown. 3. Position oil pan and install bolts. Tighten bolts to 12 Nm (105 in. lbs.). NOTE: The 2 long bolts must be tightened to 22 Nm (195 in.lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Removal > Page 2215 4. Install oil drain plug (2). 5. Lower vehicle and fill engine crankcase with proper oil to correct level. 6. Start engine and check for leaks. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Component ID: 341 Component : SWITCH-ENGINE OIL PRESSURE Connector: Name : SWITCH-ENGINE OIL PRESSURE Color : LT. GREEN # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 EOP SIGNAL G6 20VT/GY 2-Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 2219 Component Location - 15 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 2220 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 2221 Oil Pressure Sender: Diagrams Component ID: 341 Component : SWITCH-ENGINE OIL PRESSURE Connector: Name : SWITCH-ENGINE OIL PRESSURE Color : LT. GREEN # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 EOP SIGNAL G6 20VT/GY 2-Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 2222 Component Location - 15 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 2223 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Description and Operation > Description Oil Pressure Sender: Description and Operation Description DESCRIPTION The oil pressure switch is located on the left front side of the engine block. The oil pressure switch is a pressure sensitive switch that is activated by the engine's oil pressure (in the main oil gallery). The switch is a two terminal device (one terminal is provided to the wiring harness and the other terminal is the switch's metal housing that screws into the engine block). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Description and Operation > Description > Page 2226 Oil Pressure Sender: Description and Operation Operation OPERATION The oil pressure switch is normally "Closed." The switch changes from a "Closed" circuit to an "Open" circuit, on increasing pressure of 7 psig. The oil pressure switch changes from an "Open" circuit to a "Closed" circuit, on decreasing pressure, between 2 psig and 4 psig. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Service and Repair > Removal Oil Pressure Sender: Service and Repair Removal REMOVAL 1. Raise vehicle. 2. Disconnect electrical connector. 3. Remove oil pressure sensor using oil pressure socket C-4597 (1) and discard sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Service and Repair > Removal > Page 2229 Oil Pressure Sender: Service and Repair Installation INSTALLATION NOTE: If the oil pressure sensor is removed, it must be replaced with a new sensor. CAUTION: The oil pressure sensor has tapered threads, over tightening could crack the engine block. 1. Install oil pressure sensor using oil pressure socket C-4597 (1) and tighten to 8 Nm (71 in. lbs.). 2. Connect electrical connector. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure Oil Pressure Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Testing and Inspection > Checking Engine Oil Pressure Engine Oil Pressure: Testing and Inspection Checking Engine Oil Pressure CHECKING ENGINE OIL PRESSURE NOTE: Anytime the oil temperature sensor is removed, it should be replaced with a new sensor. 1. Disconnect and remove oil temperature sensor (1). CAUTION: Threads in cylinder head are British Standard Pipe (BSP). Do not install a NPT threaded adapter, this could crack the cylinder head. 2. Install threaded adapter 9879 (1). 3. Install oil pressure gauge (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Testing and Inspection > Checking Engine Oil Pressure > Page 2236 4. Start engine and record reading on oil pressure gauge (1). CAUTION: If oil pressure is 0 at idle, do not perform the 3000 RPM test 5. If oil pressure is 0 at idle, shut off engine. Check for pressure relief valve stuck open, a clogged oil pick-up screen. 6. Remove oil pan and inspect for debris. 7. Remove oil pressure relief valve. 8. Inspect oil pressure relief valve if damaged replace. 9. If pressure relief valve is ok, replace balance shaft module assembly. 10. After test is complete, remove oil pressure gauge (2) and adapter 9879 (1). 11. Install a new oil pressure temperature sensor (1) and connect electrical connector. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Testing and Inspection > Checking Engine Oil Pressure > Page 2237 Engine Oil Pressure: Testing and Inspection Checking VVT Oil Pressure CHECKING VVT OIL PRESSURE This test can be used to help diagnose VVT faults. 1. Disconnect and remove oil pressure sensor (1). CAUTION: Threads in block are 1/8"-28 British Standard Pipe (BSP). Do not install a National Pipe Thread (NPT) threaded adapter, this could crack the cylinder block. 2. Install an 1/8-28 BSP male to 1/8-27 female threaded adapter (2). 3. Install oil pressure gauge (1). 4. Start engine and record oil pressure. CAUTION: If oil pressure is 0 at idle, do not perform the 3000 RPM test 5. If oil pressure is 0 at idle, shut off engine. check for pressure relief valve stuck open, a clogged oil pick-up screen. 6. Remove oil pan and inspect for debris. 7. Remove oil pressure relief valve and inspect, if damaged replace pressure relief valve. 8. If pressure relief valve is ok, replace balance shaft module assembly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Testing and Inspection > Checking Engine Oil Pressure > Page 2238 9. After test is complete, remove test gauge (1) and fitting (2). 10. Install oil pressure sensor and electrical connector. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Oil Pressure Regulator Valve > Component Information > Service and Repair > Procedures Oil Pressure Regulator Valve: Procedures INSPECTION NOTE: Pressure regulating valve (4) can be service separately from the oil pump assembly. 1. Inspect pressure relief valve (4) scoring, gouging, or debris. Replace as needed. 2. Inspect the pressure relief valve bore in the pump for scoring, gouging, or debris. 3. If pump bore is damaged, replace balance shaft module. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Oil Pressure Regulator Valve > Component Information > Service and Repair > Procedures > Page 2243 Oil Pressure Regulator Valve: Removal and Replacement Removal REMOVAL 1. Remove oil pan 2. Remove pressure regulating valve cap (2). 3. Remove pressure regulating valve spring (3) and valve (4). Installation INSTALLATION 1. Lightly coat pressure regulating valve with clean engine oil and install valve (4). 2. Install spring (3) and cap (2). 3. Tighten cap to 44 Nm (32 lbs.ft.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature Sensor/Switch, Engine > Component Information > Locations Oil Temperature Sensor/Switch: Locations Component ID: 302 Component : SENSOR-OIL TEMPERATURE Connector: Name : SENSOR-OIL TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 EOT SIGNAL G24 20VT/BR 2 SENSOR GROUND K915 20BR/WT Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature Sensor/Switch, Engine > Component Information > Locations > Page 2247 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature Sensor/Switch, Engine > Component Information > Locations > Page 2248 Oil Temperature Sensor/Switch: Diagrams Component ID: 302 Component : SENSOR-OIL TEMPERATURE Connector: Name : SENSOR-OIL TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 EOT SIGNAL G24 20VT/BR 2 SENSOR GROUND K915 20BR/WT Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature Sensor/Switch, Engine > Component Information > Locations > Page 2249 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature Sensor/Switch, Engine > Component Information > Service and Repair > Removal Oil Temperature Sensor/Switch: Service and Repair Removal REMOVAL 1. Disconnect oil temperature sensor (1) electrical connector. 2. Remove sensor (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature Sensor/Switch, Engine > Component Information > Service and Repair > Removal > Page 2252 Oil Temperature Sensor/Switch: Service and Repair Installation INSTALLATION 1. If re-using the oil temperature sensor, coat the threads with Mopar(R) thread sealant. 2. Install oil temperature sensor (1). Tighten to 18 Nm (160 in. lbs.). 3. Connect electrical connector. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 Intake Manifold: Customer Interest A/T - MIL ON Possible DTC P2004 NUMBER: 18-032-07 GROUP: Vehicle Performance DATE: May 16, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 7.04 SPI OR HIGHER FOR THIS BULLETIN. SUBJECT: Flash: MIL Illumination with DIG P2004 OVERVIEW: This bulletin involves selectively erasing and reprogramming the GPEC Powertrain Control Module (PCM) with new software and replacing the intake manifold as required. CAUTION: VEHICLES EQUIPPED WITH A CVT TRANSMISSION MUST HAVE THE TRANSMISSION CONTROL MODULE (TCM) CHECKED FOR THE LATEST SOFTWARE LEVEL WHENEVER THE PCM SOFTWARE IS UPGRADED. IF NEWER TCM SOFTWARE IS AVAILABLE, IT MUST BE INSTALLED. MODELS: 2007-2008 (JS) Avenger 2007 (JS) Sebring 2008 (J527) Sebring Convertible 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to models equipped with a 1.8L, 2.0L or 2.4L gasoline engine (Sales Code EBA, ECN or ED3) as follows: Flash portion applies to PM/MK models built through April 21, 2007 (MDH 0421 XX) and JS models built through May 15, 2007 (0515XX). The Intake Manifold Replacement portion applies to models built through March 22, 2007 (MDHO322XX). SYMPTOM/CONDITION: Some customers may experience MIL Illumination with no other symptoms. The condition may occur intermittently. Further investigation by the technician may find DTC P2004 - Intake Manifold Runner Control Stuck Open as the cause for MIL Illumination. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine Systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Perform the standard diagnostic procedures for DIG P2004. If the diagnostics do not lead to the failure, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 2261 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and/or 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 7.04 SPI software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service> StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options d. Select "ECU Flash e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 2262 j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. m. Turn the ignition switch to the OFF position for no less than 15 seconds. n. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING 5n OR 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. PM/MK Models equipped with a CVT must have the TCM reprogrammed as follows: 6. Using the StarSCAN(R) at the "Home screen": a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. 7. Is the TCM part number recorded in step 6e above, the same as the new pin shown on the "Flash File List" screen? a. Yes > No further action is necessary. Proceed to Step 9. b. No > the TCM will require flash reprogramming, proceed to Step 8. 8. Flash reprogram the TCM as follows: a. From the "Flash File List screen, select "Download to Scantool". b. Select "Close" after the download is complete, then select "Back". c. Highlight the listed calibration. d. Select "Update Controller". Follow on screen instructions. e. When the update is complete, select "OK". f. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. g. Turn the ignition switch to the OFF position for no less than 15 seconds. h. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP Sn and 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the TCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list.** Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 2263 NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig.1). 1. Vehicles built through March 22, 2007 will require a new Intake Manifold pn 04884495AF. Following the procedures listed in DealerCONNECT > TechCONNECT replace the intake manifold. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 Intake Manifold: All Technical Service Bulletins A/T - MIL ON Possible DTC P2004 NUMBER: 18-032-07 GROUP: Vehicle Performance DATE: May 16, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 7.04 SPI OR HIGHER FOR THIS BULLETIN. SUBJECT: Flash: MIL Illumination with DIG P2004 OVERVIEW: This bulletin involves selectively erasing and reprogramming the GPEC Powertrain Control Module (PCM) with new software and replacing the intake manifold as required. CAUTION: VEHICLES EQUIPPED WITH A CVT TRANSMISSION MUST HAVE THE TRANSMISSION CONTROL MODULE (TCM) CHECKED FOR THE LATEST SOFTWARE LEVEL WHENEVER THE PCM SOFTWARE IS UPGRADED. IF NEWER TCM SOFTWARE IS AVAILABLE, IT MUST BE INSTALLED. MODELS: 2007-2008 (JS) Avenger 2007 (JS) Sebring 2008 (J527) Sebring Convertible 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to models equipped with a 1.8L, 2.0L or 2.4L gasoline engine (Sales Code EBA, ECN or ED3) as follows: Flash portion applies to PM/MK models built through April 21, 2007 (MDH 0421 XX) and JS models built through May 15, 2007 (0515XX). The Intake Manifold Replacement portion applies to models built through March 22, 2007 (MDHO322XX). SYMPTOM/CONDITION: Some customers may experience MIL Illumination with no other symptoms. The condition may occur intermittently. Further investigation by the technician may find DTC P2004 - Intake Manifold Runner Control Stuck Open as the cause for MIL Illumination. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine Systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Perform the standard diagnostic procedures for DIG P2004. If the diagnostics do not lead to the failure, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 2269 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and/or 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 7.04 SPI software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service> StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options d. Select "ECU Flash e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 2270 j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. m. Turn the ignition switch to the OFF position for no less than 15 seconds. n. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING 5n OR 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. PM/MK Models equipped with a CVT must have the TCM reprogrammed as follows: 6. Using the StarSCAN(R) at the "Home screen": a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. 7. Is the TCM part number recorded in step 6e above, the same as the new pin shown on the "Flash File List" screen? a. Yes > No further action is necessary. Proceed to Step 9. b. No > the TCM will require flash reprogramming, proceed to Step 8. 8. Flash reprogram the TCM as follows: a. From the "Flash File List screen, select "Download to Scantool". b. Select "Close" after the download is complete, then select "Back". c. Highlight the listed calibration. d. Select "Update Controller". Follow on screen instructions. e. When the update is complete, select "OK". f. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. g. Turn the ignition switch to the OFF position for no less than 15 seconds. h. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP Sn and 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the TCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list.** Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 2271 NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig.1). 1. Vehicles built through March 22, 2007 will require a new Intake Manifold pn 04884495AF. Following the procedures listed in DealerCONNECT > TechCONNECT replace the intake manifold. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 2272 Intake Manifold: Specifications Intake Manifold .................................................................................................................................... .................................................... 25 Nm (18 ft. lbs.) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 2273 Intake Manifold: Testing and Inspection INTAKE MANIFOLD LEAKS An intake manifold air leak is characterized by lower than normal manifold vacuum. Also, one or more cylinders may not be functioning. WARNING: Use extreme caution when the engine is operating. Do not stand in a direct line with the fan. Do not put your hands near the pulleys, belts or the fan. Do not wear loose clothing. 1. Start the engine. 2. Spray a small stream of water (Spray Bottle) at the suspected leak area. 3. If engine RPM'S change, the area of the suspected leak has been found. 4. Repair as required. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Procedures Intake Manifold: Procedures Cleaning CLEANING 1. Discard gasket(s). 2. Clean all sealing surfaces. Inspection INSPECTION 1. Inspect manifold for cracks, distortion, or mounting surface warpage. Replace manifold if necessary. 2. Inspect manifold gasket for surface damage or excessive swelling. Replace gaskets as necessary. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Procedures > Page 2276 Intake Manifold: Removal and Replacement Removal INTAKE MANIFOLD WARNING: Release fuel system pressure before servicing system components. Service vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the vehicle. 1. Remove engine cover (1). 2. Perform fuel system pressure release procedure before attempting any repairs. 3. Remove air cleaner inlet (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Procedures > Page 2277 4. Remove air cleaner housing (1). 5. Disconnect negative cable at battery (3). 6. Disconnect fuel line at rail (3). 7. Remove fuel injector electrical connectors (4). 8. Remove fuel rail retaining bolts and remove fuel rail. 9. Disconnect oil temperature sensor (1). 10. Disconnect variable valve timing solenoid electrical connector. 11. Disconnect intake camshaft position sensor electrical connector. 12. Position harness out of the way. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Procedures > Page 2278 13. Remove throttle body support bracket (1). 14. Disconnect electronic throttle control electrical connector. 15. Remove wiring harness retainer from the intake manifold (2). 16. Disconnect MAP sensor electrical connector. 17. Disconnect vacuum lines at intake. 18. Remove upper radiator hose retaining bracket (1). 19. Remove intake manifold retaining bolts. 20. Remove intake manifold. Installation INTAKE MANIFOLD Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Procedures > Page 2279 1. Clean all gasket surfaces. 2. Replace intake manifold gasket. 3. Install intake manifold, tighten bolts to 25 Nm (220 in. lbs.). 4. Install the fuel rail assembly to intake manifold. Tighten bolts to 23 Nm (200 in. lbs.). 5. Connect fuel injector electrical connectors. 6. Inspect quick connect fittings for damage, replace if necessary. Connect fuel supply hose to fuel rail assembly. Check connection by pulling on connector to insure it locked into position. 7. Connect negative cable to battery (3). 8. Fill the cooling system. 9. Install air cleaner housing (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Procedures > Page 2280 10. Install engine cover. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Removal Crankshaft Main Bearing Seal: Service and Repair Removal REMOVAL 1. Remove transaxle 2. Remove flex plate bolts and discard. 3. Remove flex plate (1). 4. Insert a 3/16 flat bladed screwdriver (7) between the dust lip (8) and the metal case (4) of the crankshaft seal (1). Angle the screwdriver through the dust lip against metal case of the seal. Pry out seal. CAUTION: Do not permit the screwdriver blade to contact crankshaft seal surface. Contact of the screwdriver blade against crankshaft edge (chamfer) is permitted. 5. Check to make sure the seals garter spring is not on the crankshaft. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Removal > Page 2286 Crankshaft Main Bearing Seal: Service and Repair Installation INSTALLATION CAUTION: If a burr or scratch is present on the crankshaft edge (chamfer), cleanup with 800 emery cloth to prevent seal damage during installation of new seal. If emery cloth is used, the crankshaft must be cleaned off with Mopar(R) brake parts cleaner. NOTE: When installing seal, lubricate Seal Guide 9509 with clean engine oil. 1. Place Seal Guide 9509 (3) on crankshaft. 2. Position seal (2) over guide tool. Guide tool should remain on crankshaft during installation of seal. Ensure that the lip of the seal is facing towards the crankcase during installation. 3. Drive the seal into the block using Seal Driver 9706 (1) and Driver Handle C-4171 (4) until Seal Driver 9706 bottoms out against the block. 4. Install flex plate (1). 5. Install washer (2). 6. Install new flex plate bolts (3) and tighten to 95 Nm (70 ft. lbs.). 7. Install transaxle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Removal Front Crankshaft Seal: Service and Repair Removal REMOVAL 1. Remove accessory drive belt. 2. Install damper holder 9707 (1) and remove damper retaining bolt. 3. Pull damper off crankshaft. 4. Remove front crankshaft oil seal (1) by prying out with a screw driver (2). Be careful not to damage the cover seal surface. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Removal > Page 2291 Front Crankshaft Seal: Service and Repair Installation INSTALLATION 1. Place seal (1) onto Seal installer 9506 (2) with seal spring towards the inside of engine. 2. Install new seal (1) by using Seal installer 9506 (2) and crankshaft damper bolt (3). 3. Press seal into front cover until Seal Installer 9506 (1) seats against timing chain cover (3). 4. Remove seal installer 9506 (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Removal > Page 2292 5. Install crankshaft vibration damper. 6. Oil the bolt threads and between the bolt head and washer. 7. Install damper retaining bolt and damper holder 9707 (1). Tighten bolt to 50 Nm + 68° (37 ft. lbs. + 68°). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Component ID: 341 Component : SWITCH-ENGINE OIL PRESSURE Connector: Name : SWITCH-ENGINE OIL PRESSURE Color : LT. GREEN # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 EOP SIGNAL G6 20VT/GY 2-Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 2297 Component Location - 15 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 2298 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 2299 Oil Pressure Sender: Diagrams Component ID: 341 Component : SWITCH-ENGINE OIL PRESSURE Connector: Name : SWITCH-ENGINE OIL PRESSURE Color : LT. GREEN # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 EOP SIGNAL G6 20VT/GY 2-Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 2300 Component Location - 15 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 2301 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Description and Operation > Description Oil Pressure Sender: Description and Operation Description DESCRIPTION The oil pressure switch is located on the left front side of the engine block. The oil pressure switch is a pressure sensitive switch that is activated by the engine's oil pressure (in the main oil gallery). The switch is a two terminal device (one terminal is provided to the wiring harness and the other terminal is the switch's metal housing that screws into the engine block). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Description and Operation > Description > Page 2304 Oil Pressure Sender: Description and Operation Operation OPERATION The oil pressure switch is normally "Closed." The switch changes from a "Closed" circuit to an "Open" circuit, on increasing pressure of 7 psig. The oil pressure switch changes from an "Open" circuit to a "Closed" circuit, on decreasing pressure, between 2 psig and 4 psig. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Service and Repair > Removal Oil Pressure Sender: Service and Repair Removal REMOVAL 1. Raise vehicle. 2. Disconnect electrical connector. 3. Remove oil pressure sensor using oil pressure socket C-4597 (1) and discard sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Service and Repair > Removal > Page 2307 Oil Pressure Sender: Service and Repair Installation INSTALLATION NOTE: If the oil pressure sensor is removed, it must be replaced with a new sensor. CAUTION: The oil pressure sensor has tapered threads, over tightening could crack the engine block. 1. Install oil pressure sensor using oil pressure socket C-4597 (1) and tighten to 8 Nm (71 in. lbs.). 2. Connect electrical connector. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Locations Oil Temperature Sensor/Switch: Locations Component ID: 302 Component : SENSOR-OIL TEMPERATURE Connector: Name : SENSOR-OIL TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 EOT SIGNAL G24 20VT/BR 2 SENSOR GROUND K915 20BR/WT Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Locations > Page 2311 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Locations > Page 2312 Oil Temperature Sensor/Switch: Diagrams Component ID: 302 Component : SENSOR-OIL TEMPERATURE Connector: Name : SENSOR-OIL TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 EOT SIGNAL G24 20VT/BR 2 SENSOR GROUND K915 20BR/WT Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Locations > Page 2313 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Service and Repair > Removal Oil Temperature Sensor/Switch: Service and Repair Removal REMOVAL 1. Disconnect oil temperature sensor (1) electrical connector. 2. Remove sensor (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Service and Repair > Removal > Page 2316 Oil Temperature Sensor/Switch: Service and Repair Installation INSTALLATION 1. If re-using the oil temperature sensor, coat the threads with Mopar(R) thread sealant. 2. Install oil temperature sensor (1). Tighten to 18 Nm (160 in. lbs.). 3. Connect electrical connector. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Description and Operation > Variable Valve Timing Assembly - Description Camshaft Gear/Sprocket: Description and Operation Variable Valve Timing Assembly - Description DESCRIPTION The world engine is equipped with Variable Valve Timing (VVT). This system advances and/or retards intake and/or exhaust camshaft timing to improve engine performance, mid-range torque, idle quality, fuel economy, and reduce emissions. The camshaft sprockets are integrated with the VVT assemblies and are serviced as an assembly. VVT assemblies are sometimes referred to as camshaft phasers. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Description and Operation > Variable Valve Timing Assembly - Description > Page 2322 Camshaft Gear/Sprocket: Description and Operation Variable Valve Timing Assembly - Operation OPERATION The Variable Valve Timing (VVT) assemblies are actuated with engine oil pressure. The oil flow to the VVT assemblies are controlled by two Oil Control Valves (OCV). There is an OCV and Camshaft Position Sensor (CMP) for each camshaft. The OCV's consist of a Pulse Width Modulated (PWM) solenoid and a spool valve. The PCM actuates the OCV to control oil flow through the spool valve into the VVT assemblies. The VVT assembly consists of a rotor, stator, and sprocket. The stator is connected to the timing chain through the sprocket. The rotor is connected to the camshaft. Oil flow in to the VVT assembly rotates the rotor with respect to the stator, thus rotating the camshaft with respect to the timing chain. Thus, the VVT assemblies change valve timing by changing the relationship between the camshaft and the timing chain. An infinitely variable valve timing position can be achieved within the limits of the hardware. The CMP monitors the position of the camshaft with respect to the crankshaft and provides feedback to the PCM. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Service and Repair > Camshaft Sprockets - Removal Camshaft Gear/Sprocket: Service and Repair Camshaft Sprockets - Removal REMOVAL NOTE: Camshaft phaser and camshaft sprocket are supplied as an assembly, do not attempt to disassemble. 1. Remove camshafts. 2. Remove camshaft phaser (2) retaining bolt while holding the camshaft in place with a wrench (1) on the camshaft flats. 3. Remove phaser (2) assembly from camshaft. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Service and Repair > Camshaft Sprockets - Removal > Page 2325 Camshaft Gear/Sprocket: Service and Repair Camshaft Sprockets - Installation INSTALLATION CAUTION: Do not use an impact wrench to tighten camshaft sprocket bolts. Damage to the camshaft-to-sprocket locating dowel pin and camshaft phaser may occur. 1. Install phaser (2) assembly on camshaft. NOTE: Make sure the dowel is seated in the dowel hole and not in a oil feed hole. The dowel hole is larger than the 4 oil feed holes. 2. Install phaser retaining bolt and torque while holding camshaft in place with a wrench (1). 3. Install camshafts. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Procedures Timing Chain: Procedures INSPECTION Inspect timing chain for stretching prior to removal. 1. Rotate engine while watching timing chain tensioner plunger. When the plunger reaches its maximum travel stop rotating engine. 2. Measure the distance from the tensioner body and the edge of the chain guide as shown. 3. If the distance is greater than 20.5 mm (0.81 in.) inspect guide shoes for excessive wear. 4. If guides are okay, replace timing chain. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Procedures > Page 2330 Timing Chain: Removal and Replacement Removal - Camshaft Sprocket(s) CAMSHAFT SPROCKET(S) NOTE: Camshaft phasers and camshaft sprockets are supplied as an assembly, do not attempt to disassemble. Refer to camshaft phaser removal Refer to CAMSHAFT(S) - REMOVAL. Installation - Camshaft Sprocket(s) CAMSHAFT SPROCKET(S) NOTE: The camshaft sprockets and the camshaft phasers are an assembly and cannot be serviced separately. CAUTION: Do not use an impact wrench to tighten camshaft sprocket bolts. Damage to the camshaft-to-sprocket locating dowel pin and camshaft phaser may occur. 1. Refer to Camshaft phaser installation. Removal - Crankshaft Sprocket CRANKSHAFT SPROCKET 1. Remove timing chain. 2. Remove oil pan. 3. Remove oil pump drive chain tensioner. 4. Remove oil pump drive chain. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Procedures > Page 2331 5. Remove crankshaft sprocket (1). Installation - Crankshaft Sprocket CRANKSHAFT SPROCKET 1. Install crankshaft sprocket (1) onto crankshaft. 2. Install oil pump drive chain. Verify that Oil pump is correctly timed (1, 2, 5, 6). 3. Reset oil pump drive chain tensioner by pushing plunger inward and install tensioner pin 8514. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Procedures > Page 2332 4. Install oil pump drive chain tensioner (3) and remove Tensioner Pin 8514 (4). 5. Install timing chain. 6. Install oil pan. 7. Fill engine with oil. 8. Start engine and check for leaks. Removal - Timing Chain TIMING CHAIN 1. Set engine to TDC. 2. Remove timing chain cover. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Procedures > Page 2333 NOTE: If the timing chain plated links can no longer be seen, the timing chain links corresponding to the timing marks must be marked prior to removal if the chain is to be reused. 3. Mark chain link (1) corresponding to camshaft timing mark. 4. Mark chain link (3) corresponding to crankshaft timing mark (2). 5. Remove timing chain tensioner (5). 6. Remove timing chain (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Procedures > Page 2334 Installation - Timing Chain TIMING CHAIN 1. Verify that the crankshaft sprocket keyway is at the 9 o'clock position. 2. Align camshaft timing marks (3) so they are parallel to the cylinder head and aligned each other as shown. 3. Install timing chain guide (4) and tighten bolts to 12 Nm (105 in. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Procedures > Page 2335 4. Install timing chain so plated links on chain align with timing marks on camshaft sprockets (1). 5. Align timing mark on the crankshaft sprocket (2) with the plated link (3) on the timing chain. Position chain so slack will be on the tensioner side. NOTE: Keep the slack in the timing chain on the tensioner side. 6. Install the moveable timing chain pivot guide (6) and tighten bolt to 12 Nm (105 in. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Procedures > Page 2336 7. Reset timing chain tensioner (4) by lifting up on ratchet (2) and pushing plunger (3) inward towards the tensioner body (4). Insert Tensioner Pin 8514 into slot (1) to hold tensioner plunger in the retracted position. 8. Install timing chain tensioner (1) and tighten bolts to 12 Nm (105 in. lbs.). 9. Remove timing Tensioner Pin 8514 (2). 10. Rotate the crankshaft CLOCKWISE two complete revolutions until the crankshaft is repositioned at the TDC position with the key way at the 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Procedures > Page 2337 o'clock position. 11. Verify that the camshafts timing marks (3) are in the proper position. 12. Install front timing chain cover. 13. Install the balancer and verify that balancer mark (2) and cover mark (1) are aligned. 14. Connect negative battery cable. 15. Fill with oil, start engine and check for leaks. Removal REMOVAL 1. Remove engine cover by pulling upward. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Procedures > Page 2338 2. Perform fuel pressure bleed procedure. 3. Disconnect negative cable at battery (3). 4. Remove coolant recovery bottle (3). 5. Remove windshield washer bottle (1). 6. Remove power steering reservoir (2) and set aside. 7. Remove make up air hose (2). 8. Remove PCV hose (5). 9. Disconnect ignition coil electrical connectors (1). 10. Remove cylinder head cover. 11. Raise vehicle. 12. Remove right lower splash shield. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Procedures > Page 2339 13. Set engine to TDC (1). 14. Remove accessory drive belt. 15. Remove lower A/C compressor (1) retaining bolts. 16. Remove A/C compressor lower bracket (2). 17. Remove accessory drive belt lower idler pulley. 18. Remove crankshaft damper (2). 19. Remove front crankshaft oil seal. 20. Remove water pump pulley (4). 21. Remove engine mount bracket (1) lower bolt. 22. Remove timing chain cover lower bolts (1). 23. Lower vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Procedures > Page 2340 24. Remove power steering line support (1). 25. Remove power steering pump and set aside. 26. Support engine with a suitable jack and a block of wood under the oil pan. 27. Remove right engine mount to mount bracket bolts (3). 28. Remove accessory drive belt upper idler pulley. 29. Remove right engine mount bracket (1). 30. Remove accessory drive belt tensioner. 31. Remove timing chain cover retaining bolts. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Procedures > Page 2341 32. Remove timing chain cover using pry points (1, 2, 3). 33. Remove timing chain cover (1) out through the bottom of the vehicle. Installation INSTALLATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Procedures > Page 2342 NOTE: When using RTV, the sealing surfaces must be clean and free from grease and oil. NOTE: When using RTV, parts should be assembled in 10 minutes and tighten to final torque within 45 minutes. 1. Clean all sealing surfaces. 2. Apply Mopar(R) engine sealant RTV or equivalent as shown at the cylinder head to block parting line (1, 2). 3. Apply Mopar(R) engine sealant RTV or equivalent as shown at the ladder frame to block parting line (1, 2). 4. Apply Mopar(R) engine sealant RTV or equivalent as shown in the corner of the oil pan and block. 5. Apply 2 mm bead of Mopar(R) engine sealant RTV or equivalent to the oil pan as shown. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Procedures > Page 2343 6. Apply 2 mm bead of Mopar(R) engine sealant RTV or equivalent to the engine block (1,2) as shown. 7. Install timing chain cover (1) upwards from under the vehicle. 8. Install timing chain cover upper retaining bolts and tighten M6 bolts to 12 Nm (105 in lbs) and M8 bolts to 23 Nm (204 in lbs). 9. Install accessory drive belt tensioner. 10. Install right engine mount bracket (1). 11. Install accessory drive belt upper idler pulley. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Procedures > Page 2344 12. Install right engine mount (1). 13. Remove jack from under engine. 14. Install power steering pump. 15. Raise vehicle. 16. Install oil pan to timing chain cover lower retaining bolts (1) and tighten bolts. 17. Install timing chain cover retaining bolts and tighten bolts. 18. Install water pump pulley (4). 19. Install crankshaft pulley (2) and tighten bolt. 20. Install accessory drive belt lower idler pulley. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Procedures > Page 2345 21. Install lower A/C compressor mounting bracket (2). 22. Install A/C compressor (1). 23. Install accessory drive belt. 24. Install right lower splash shield. 25. Lower vehicle. 26. Install cylinder head cover. 27. Connect coil electrical connectors (1). 28. Connect PCV hose (5) to PCV valve. 29. Connect make up air hose (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Procedures > Page 2346 30. Install power steering reservoir (2). 31. Install windshield washer bottle (1). 32. Install coolant recovery bottle (3). 33. Fill cooling system. 34. Install air cleaner housing inlet (2). 35. Connect negative cable to battery (3). 36. Install engine cover. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications Timing Chain Tensioner: Specifications Timing Chain Tensioner Assembly-Bolts .............................................................................................................................................. 12 Nm (105 in. lbs.) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Removal Timing Chain Tensioner: Service and Repair Removal REMOVAL 1. Remove timing chain. NOTE: Tensioner will not come apart during removal. 2. Remove timing chain tensioner retaining bolts and remove tensioner. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Removal > Page 2352 Timing Chain Tensioner: Service and Repair Installation INSTALLATION 1. Reset tensioner. 2. Install timing chain. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Component Alignment Marks > Component Information > Locations Timing Component Alignment Marks: Locations ^ Verify that the crankshaft sprocket keyway is at the 9 o'clock position. ^ Align camshaft timing marks (3) so they are parallel to the cylinder head and aligned each other as shown. ^ Install timing chain so plated links on chain align with timing marks on camshaft sprockets (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Component Alignment Marks > Component Information > Locations > Page 2356 ^ Align timing mark on the crankshaft sprocket (2) with the plated link (3) on the timing chain. Position chain so slack will be on the tensioner side. ^ Rotate the crankshaft CLOCKWISE two complete revolutions until the crankshaft is repositioned at the TDC position with the key way at the 9 o'clock position. ^ Verify that the camshafts timing marks (3) are in the proper position. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Component Alignment Marks > Component Information > Locations > Page 2357 ^ Install the balancer and verify that balancer mark (2) and cover mark (1) are aligned. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Timing Chain Cover M6 Bolts ............................................................................................................................................... ............................................. 12 Nm (105 in. lbs.) M8 Bolts ................................................................ ............................................................................................................................ 23 Nm (204 in. lbs.) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Removal Timing Cover: Service and Repair Removal REMOVAL 1. Remove engine cover by pulling upward. 2. Perform fuel pressure bleed procedure. 3. Disconnect negative cable at battery (3). 4. Remove coolant recovery bottle (3). 5. Remove windshield washer bottle (1). 6. Remove power steering reservoir (2) and set aside. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Removal > Page 2363 7. Remove make up air hose (2). 8. Remove PCV hose (5). 9. Disconnect ignition coil electrical connectors (1). 10. Remove cylinder head cover. 11. Raise vehicle. 12. Remove right lower splash shield. 13. Set engine to TDC (1). 14. Remove accessory drive belt. 15. Remove lower A/C compressor (1) retaining bolts. 16. Remove A/C compressor lower bracket (2). 17. Remove accessory drive belt lower idler pulley. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Removal > Page 2364 18. Remove crankshaft damper (2). 19. Remove front crankshaft oil seal. 20. Remove water pump pulley (4). 21. Remove engine mount bracket (1) lower bolt. 22. Remove timing chain cover lower bolts (1). 23. Lower vehicle. 24. Remove power steering line support (1). 25. Remove power steering pump and set aside. 26. Support engine with a suitable jack and a block of wood under the oil pan. 27. Remove right engine mount to mount bracket bolts (3). 28. Remove accessory drive belt upper idler pulley. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Removal > Page 2365 29. Remove right engine mount bracket (1). 30. Remove accessory drive belt tensioner. 31. Remove timing chain cover retaining bolts. 32. Remove timing chain cover using pry points (1, 2, 3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Removal > Page 2366 33. Remove timing chain cover (1) out through the bottom of the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Removal > Page 2367 Timing Cover: Service and Repair Installation INSTALLATION NOTE: When using RTV, the sealing surfaces must be clean and free from grease and oil. NOTE: When using RTV, parts should be assembled in 10 minutes and tighten to final torque within 45 minutes. 1. Clean all sealing surfaces. 2. Apply Mopar(R) engine sealant RTV or equivalent as shown at the cylinder head to block parting line (1, 2). 3. Apply Mopar(R) engine sealant RTV or equivalent as shown at the ladder frame to block parting line (1, 2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Removal > Page 2368 4. Apply Mopar(R) engine sealant RTV or equivalent as shown in the corner of the oil pan and block. 5. Apply 2 mm bead of Mopar(R) engine sealant RTV or equivalent to the oil pan as shown. 6. Apply 2 mm bead of Mopar(R) engine sealant RTV or equivalent to the engine block (1,2) as shown. 7. Install timing chain cover (1) upwards from under the vehicle. 8. Install timing chain cover upper retaining bolts and tighten M6 bolts to 12 Nm (105 in lbs) and M8 bolts to 23 Nm (204 in lbs). 9. Install accessory drive belt tensioner. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Removal > Page 2369 10. Install right engine mount bracket (1). 11. Install accessory drive belt upper idler pulley. 12. Install right engine mount (1). 13. Remove jack from under engine. 14. Install power steering pump. 15. Raise vehicle. 16. Install oil pan to timing chain cover lower retaining bolts (1) and tighten bolts. 17. Install timing chain cover retaining bolts and tighten bolts. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Removal > Page 2370 18. Install water pump pulley (4). 19. Install crankshaft pulley (2) and tighten bolt. 20. Install accessory drive belt lower idler pulley. 21. Install lower A/C compressor mounting bracket (2). 22. Install A/C compressor (1). 23. Install accessory drive belt. 24. Install right lower splash shield. 25. Lower vehicle. 26. Install cylinder head cover. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Removal > Page 2371 27. Connect coil electrical connectors (1). 28. Connect PCV hose (5) to PCV valve. 29. Connect make up air hose (2). 30. Install power steering reservoir (2). 31. Install windshield washer bottle (1). 32. Install coolant recovery bottle (3). 33. Fill cooling system. 34. Install air cleaner housing inlet (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Removal > Page 2372 35. Connect negative cable to battery (3). 36. Install engine cover. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Locations > Solenoid-Camshaft 1/1 Position Variable Valve Timing Solenoid: Locations Solenoid-Camshaft 1/1 Position Component ID: 325 Component : SOLENOID-CAMSHAFT 1/1 POSITION Connector: Name : SOLENOID-CAMSHAFT 1/1 POSITION Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 CMP 1/1 CONTROL K76 20LB/WT 2 FUSED MAIN RELAY OUTPUT K343 16BR/YL Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Locations > Solenoid-Camshaft 1/1 Position > Page 2378 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Locations > Solenoid-Camshaft 1/1 Position > Page 2379 Variable Valve Timing Solenoid: Locations Solenoid-Camshaft 1/2 Position Component ID: 326 Component : SOLENOID-CAMSHAFT 1/2 POSITION Connector: Name : SOLENOID-CAMSHAFT 1/2 POSITION Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 CMP 1/2 CONTROL K276 20DB/WT 2 FUSED MAIN RELAY OUTPUT K343 16BR/YL Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Locations > Solenoid-Camshaft 1/1 Position > Page 2380 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Diagrams > Solenoid-Camshaft 1/1 Position Variable Valve Timing Solenoid: Diagrams Solenoid-Camshaft 1/1 Position Component ID: 325 Component : SOLENOID-CAMSHAFT 1/1 POSITION Connector: Name : SOLENOID-CAMSHAFT 1/1 POSITION Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 CMP 1/1 CONTROL K76 20LB/WT 2 FUSED MAIN RELAY OUTPUT K343 16BR/YL Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Diagrams > Solenoid-Camshaft 1/1 Position > Page 2383 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Diagrams > Solenoid-Camshaft 1/1 Position > Page 2384 Variable Valve Timing Solenoid: Diagrams Solenoid-Camshaft 1/2 Position Component ID: 326 Component : SOLENOID-CAMSHAFT 1/2 POSITION Connector: Name : SOLENOID-CAMSHAFT 1/2 POSITION Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 CMP 1/2 CONTROL K276 20DB/WT 2 FUSED MAIN RELAY OUTPUT K343 16BR/YL Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Diagrams > Solenoid-Camshaft 1/1 Position > Page 2385 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Description and Operation > Description Variable Valve Timing Solenoid: Description and Operation Description DESCRIPTION Variable valve timing solenoid assembly. The solenoid receives pulse width modulation signal and the current is controlled within 0 ma to 1000 ma. The spool position is controllable at any position to control supply of oil between the advance and retard ports. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Description and Operation > Description > Page 2388 Variable Valve Timing Solenoid: Description and Operation Operation OPERATION There is both an Intake and an exhaust camshaft sensor on vehicles equipped with a World Engine. The variable valve timing system used on World Engines requires the exact position of both the intake and exhaust camshaft. The GPEC1 uses camshaft sensor data along with crankshaft data to determine the actual position of the camshafts. Intake and exhaust phaser oil control valves are required on World Engine vehicles using variable valve timing. The oil valves direct oil to the Intake and exhaust phasers. Oil pressure in the phasers moves the camshafts to an advanced or retarded position. To resolve this inherent conflict between optimum high and low speed valve timing, the GPEC1 controlled engine uses a variable valve timing system. The variable valve timing system advances and retards valve timing by rotating the position of both the intake and exhaust camshafts. With this system, the intake valve opening can range from 80 to 120 crankshaft degrees after Top Dead Center. Likewise, the exhaust valve opening can range from 85 to 120 crankshaft degrees before Top Dead Center. This degree of flexibility provides many benefits, including: Improved Engine Performance, Increased Fuel Economy, Improved Idle Stability and Decreased Engine Emissions. In non operating condition, the camshaft stays in lockpin position of cam phases. This is 120 degrees ATDC for intake camshaft and 120 degrees BTDC for exhaust camshaft. The variable valve timing system is electronically controlled and hydraulically operated. The GPEC1 receives information from many sensors to determine the optimum valve timing. It then pulse-width modulates oil control valves which direct oil to the cam phasers. The cam phasers use oil pressure to rotate the intake and exhaust camshafts. The rotation of the camshafts is referred to as cam phasing. Before the GPEC1 can begin commanding the camshaft phasing, several enabling conditions must be met: - The engine oil temperature must be at least -6.6° C (20° F) - The oil control valve coil temperature must be less than 140° C (284° F) - Engine speed must be at least 600 to 1000 rpm to achieve minimum oil pressure. - Battery voltage must be at least 10 volts - And there must be no camshaft or crankshaft sensor faults, engine timing faults, or oil control valve faults First we will examine variable valve timing enabling conditions, and then we will take a closer look at the inputs and outputs of the system: - Accelerator pedal position sensor - Oil temperature sensor - Map sensor - Intake cam sensor - Exhaust cam sensor - Crankshaft sensor - GPEC1 - Exhaust phaser oil control valve - Intake phaser oil control valve - Inputs - Engine control module - Outputs - Sensed battery voltage A minimum oil temperature is required to enable variable valve timing operation. Oil temperature and viscosity also have an impact on the operation of variable valve timing after start-up. Oil is used to control the movement of the camshafts. An incorrect oil viscosity could adversely affect the operation of the system or even render the system inoperative. It may even set a fault code. The accelerator pedal position sensor indicates how far the driver wants to open the throttle plate. The GPEC1 calculates an initial camshaft set point based on whether the accelerator pedal is at part throttle or wide open throttle. The MAP sensor provides information regarding engine load. Sensed battery voltage provides information regarding current system voltage. Sensed battery voltage must be at least 10 volts in order for the oil control valves to function properly. This information allows the GPEC1 to adjust camshaft timing to achieve the best fuel economy, the best engine performance or a combination of both. The hall-effect crankshaft sensor provides RPM information and determines when the number one piston is approaching Top Dead Center. The sensor generates a signal as the tone wheel, attached to the crankshaft, rotates. The tone wheel has 60 teeth minus two. When the gap, created by the missing teeth passes by the sensor, a signal is produced that indicates the number one piston is at Top Dead Center. The GPEC1 uses crankshaft sensor data along with camshaft data to determine the actual position of the camshaft. There are two hall-effect camshaft sensors on engines equipped with variable valve timing. The GPEC1 uses camshaft sensor data along with crankshaft data to determine the actual position of the camshaft. The GPEC1 individually controls each valve. It sends a pulse width modulated signal to move a spool within the outer casing of the valve. Depending upon spool movement, oil is directed through the passages to advance or retard cam timing. The oil control valve also has a special cleaning strategy at Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Description and Operation > Description > Page 2389 key-on. The cleaning strategy is known as "debris crush mode". At key-on the GPEC1 cycles the oil control valve on and off several (5) times to crush any debris in the oil control valve and prevent the spool valve from sticking. In non operating condition, the camshaft stays in lockpin position of cam phases. This is 120 degrees ATDC for intake camshaft and 120 degrees BTDC for exhaust camshaft. There are two oil control valves. One valve directs oil to the intake cam phaser, the other valve directs oil to the exhaust cam phaser. The valves are designed and function in the same manner. The outer casing of each oil valve has five oil passages. A passage for pressurized supply oil. A passage to the advance chamber of the cam phaser. A passage to the retard chamber of the cam phaser. A passage for oil return from the advance chamber of the cam phaser. A passage for oil return from the retard chamber of the cam phaser. Oil flows through the passages and applies pressure to the cam phasers to change cam timing. There are two cam phasers. One phaser controls the position of the intake camshaft. The other phaser controls the position of the exhaust camshaft. The phasers consist of a sprocket, a rotor vane, and a housing or stator. The exhaust cam phaser also consists of a front bushing and spring. We will discuss the purpose and function of the bushing and spring later. The housing is bolted and permanently fixed to the camshaft sprocket, while the rotor vane is bolted and permanently fixed to the camshaft. With this design, any movement of the rotor vane in relation to the housing will also move the camshaft. The phaser and sprocket are serviced as an assembly. Camshaft and crankshaft sensors provide feedback to the GPEC1 regarding the actual position of the camshafts. The GPEC1 then compares the actual camshaft positioning with desired positioning. If the desired positioning is not achieved within a specified time, during the second key cycle a trouble code is set. There are six new diagnostic trouble codes available to help you determine if the control circuit from the GPEC1 to the oil control valve is intact and operating properly. The codes identify whether the control circuit is open, shorted to ground, or shorted to power. Three trouble codes are related to intake camshaft positioning, the other three codes are specific to exhaust camshaft positioning. The oil control valve contains both electrical and mechanical components. It is electrically controlled by the GPEC1. The electrical current that energizes the coil results in mechanical motion of the spool valve. It is possible to verify both the electrical and mechanical operation of the valve. The oil control valve consists of a coil that is energized to move a spool within an outer casing. The condition of the coil can be tested with a Digital Volt Ohmmeter or DVOM. With the DVOM set to measure resistance, check the coil for an open, a short to ground, or excessive resistance. The correct resistance value of the coil is between 6 and 8 ohms. The mechanical operation of the oil control valve can be tested using actuator commands on the scan tool. Remove the oil control valve, then navigate to the actuator menu and select the oil control valve. Use commands to activate the valve and watch as the spool valve moves back and forth inside the casing. Because the cam phasers are hydraulically operated by engine oil, the condition of the oil is very important. The oil must be of the correct viscosity, not obstructed by debris, to maintain correct pressure. Maintaining the correct oil viscosity is critical to the operation of the variable valve timing system. The wrong oil viscosity may cause the variable valve timing to malfunction and trouble codes to set. The correct oil viscosity for this system is 5W20. Oil must be clean, unobstructed and free to flow through the variable valve timing system. Oil could become obstructed in oil passages located in the cylinder head, cylinder block, or even in the oil screen. In the event oil flow is obstructed, further diagnosis or disassembly may be required to pin point the source of the obstruction. The variable valve timing system relies on oil pressure to advance or retard the position of the camshaft. Insufficient oil pressure will adversely affect the operation of variable valve timing. The minimum oil pressure for this system is 15 psi at normal operating temperature. Though not directly used to change camshaft positioning, the oil screen is an important component of the variable valve timing system. It helps to remove debris going to the variable valve timing components. The oil screen is located in the cylinder block, immediately below the cylinder head. Oil must pass through the oil screen before entering the oil control valve. The cylinder head must be removed to service the oil screen. The intention is not to service the oil screen during vehicle life. How the cam phaser works. The cam phaser assembly has eight separate chambers; four advance chambers and four retard chambers. When camshaft advance is requested, oil enters all four advance chambers and exerts force on the rotor vane. Because the rotor vane is bolted to the camshaft, the entire camshaft profile moves along with the rotor vane. At the same time, oil is forced out of the retard chambers. When camshaft retard is requested oil enters the retard chambers to move the camshaft in the opposite direction. There is a lock pin on one side of the rotor vane that fits inside a recessed area in the housing. The lock pin ensures that the default position of the intake cam phaser is 120 crankshaft degrees full retard and the default position of the exhaust cam phaser is 120 crankshaft degrees full advance. When the engine is turned off, rotational force and inertia move the intake camshaft and rotor vane toward the retard position. The exhaust cam phaser includes a spring and bushing to work against the rotational force of the engine, allowing the exhaust cam phaser to lock in the fully advanced position. Under most conditions the cam phasers are returned to lock pin position when the engine is turned off. In the unique condition of an engine stall, which abruptly shuts off the engine, the cam phasers may not return to the lock pin position. In this case, the phasers will return to the lock pin position at the next start-up. Lock pin position is the most ideal cam timing for idle stability. When engine rpm exceeds approximately 600 to 1000 rpm, oil pressure unlocks the pins and variable valve timing resumes. Once enabling conditions are met, the GPEC1 uses input from sensors to calculate optimum valve timing. There are four preprogrammed modes from which the GPEC1 bases initial valve timing. - Starting - Idle or Part throttle - Wide open throttle - Limp-in or Default From each preprogrammed mode, the GPEC1 adjusts valve timing based on operating conditions. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Description and Operation > Description > Page 2390 GPEC1 has calculated optimum intake valve timing of 112 degrees after Top Dead Center and optimum exhaust valve timing of 97 degrees before Top Dead Center. The GPEC1 pulse width modulates the oil control valves to advance or retard the camshaft to their desired location. The spool valve inside the intake oil control valve is energized and moves to allow pressurized oil into the advance chambers of the intake cam phaser. At the same time, the spool valve inside the exhaust oil control valve is energized and moves to allow pressurized oil into the retard chambers of the exhaust cam phaser. Oil enters the advance chambers of the intake phaser and the retard chambers of the exhaust phaser. Oil pressure releases the lock pin from its locked position and pushes against the rotor vane. Both the rotor vanes are moved, advancing the intake camshaft and retarding the exhaust camshaft. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Service and Repair > Variable Valve Timing Solenoid Removal Variable Valve Timing Solenoid: Service and Repair Variable Valve Timing Solenoid - Removal Front Solenoid 1/1 FRONT SOLENOID 1/1 1. Disconnect negative battery cable. 2. Remove engine cover. 3. Rotate hose clamp out of way. 4. Disconnect oil pressure sensor electrical connector. 5. Remove oil pressure sensor. 6. Disconnect variable valve timing solenoid electrical connector. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Service and Repair > Variable Valve Timing Solenoid Removal > Page 2393 7. Remove variable valve timing solenoid mounting bolt. 8. Pull solenoid straight out of cylinder head. Rear Solenoid 1/2 REAR SOLENOID 1/2 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Service and Repair > Variable Valve Timing Solenoid Removal > Page 2394 1. Disconnect negative battery cable. 2. Remove engine cover. 3. Disconnect variable valve timing solenoid electrical connector. 4. Remove variable valve timing solenoid mounting bolt. 5. Pull solenoid straight out of cylinder head. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Service and Repair > Variable Valve Timing Solenoid Removal > Page 2395 Variable Valve Timing Solenoid: Service and Repair Variable Valve Timing Solenoid - Installation Front Solenoid 1/1 FRONT SOLENOID 1/1 1. Solenoid for front location 1/1. Note mounting tab location is different between front and rear solenoids. 2. Install solenoid into cylinder head. 3. Install mounting bolt and tighten to 12 Nm (9 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Service and Repair > Variable Valve Timing Solenoid Removal > Page 2396 4. Install oil pressure sensor. 5. Connect electrical connector to oil pressure sensor. 6. Connect electrical connector to Variable valve timing solenoid. 7. Connect negative battery cable. 8. Install engine cover. Rear Solenoid 1/2 REAR SOLENOID 1/2 1. Rear variable valve timing solenoid. Note mounting tab location is different between front and rear solenoids. 2. Install solenoid into cylinder head. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Service and Repair > Variable Valve Timing Solenoid Removal > Page 2397 3. Install mounting bolt and tighten to 12 Nm (9 ft. lbs.). 4. Connect electrical connector to Variable valve timing solenoid. 5. Connect negative battery cable. 6. Install engine cover. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL SYSTEM PRESSURE Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2402 Fuel Pressure: Testing and Inspection *CHECKING THE FUEL DELIVERY SYSTEM For a complete wiring diagram refer to Diagrams/Electrical. Diagnostic Test 1. CHECKING THE FUEL PUMP OPERATION Turn the ignition on. NOTE: Diagnose and repair any fuel pump control circuit or relay DTCs before continuing with this test. With a scan tool, actuate the fuel pump control to ON (100%). NOTE: It may be necessary to use a mechanics stethoscope in the next step. Listen for fuel pump operation at the fuel tank. The fuel pump should operate smoothly, without excessive noise. If necessary, compare to a known good vehicle of similar year, make, and model. NOTE: If the pump has excessive noise or grinding, the pump should be replaced. caution: Stop all actuation tests before continuing. Is the fuel pump operating when actuated? Yes - Go to 2 No - Go to 7 2. CHECKING THE FUEL PRESSURE Turn the ignition off. WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in personal injury or death. Install a fuel pressure gauge on the fuel rail. Turn the ignition on. With the scan tool, actuate the fuel pump relay control. Observe the fuel pressure gauge. NOTE: The fuel pressure specification is 407 KPa ± 34 KPa (59 psi ± 5 psi). caution: Stop all actuation tests before continuing. Select the conclusion that best matches the result of the test: Fuel pressure is within the stated specification - Test complete. Fuel pressure is below the stated specification - Go to 3 Fuel pressure is above the stated specification - Replace the fuel filter/pressure regulator. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2403 - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 3. RESTRICTED FUEL SUPPLY LINE Turn the ignition off. WARNING: The fuel system is under a constant pressure, even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in personal injury or death. Raise vehicle on hoist, and disconnect the fuel pressure line at the fuel pump module. Install special 5/16 fuel line adapter tool #6539 between disconnected fuel line and the fuel pump module. Attach a fuel pressure test gauge to the T fitting on tool #6539. Turn the ignition on. With the scan tool, actuate the fuel pump relay control. Observe the fuel pressure gauge. NOTE: Fuel pressure specification is 407 KPa ± 34 KPa (59 psi ± 5 psi). caution: Stop all actuation tests before proceeding. Is the fuel pressure within specification? Yes - Repair or replace fuel supply line as necessary. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 4 4. SADDLE FUEL TANK Is the vehicle equipped with a saddle type fuel tank? Yes - Go to 5 No - Go to 6 5. FUEL TANK SIPHON HOSE OR FUEL LINE RESTRICTED OR DAMAGED Turn the ignition off. WARNING: The fuel system is under a constant pressure, even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in personal injury or death. Gain access to the fuel pump module and the fuel tank module. Inspect the fuel line and siphon hose between the fuel pump module and the fuel tank module. Look for disconnected or damaged lines and hoses. Inspect the fuel pressure regulator for damage or a condition that might cause a fuel flow problem. Make sure that it is seated in the module properly. Were any problems found? Yes - Repair as necessary. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2404 - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 6 6. FUEL PUMP INLET STRAINER Turn the ignition off. WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in personal injury or death. Remove the fuel pump module and inspect the fuel inlet strainer for damage or a condition that might cause a fuel flow problem. Were any problems found? Yes - Replace the Fuel Pump Inlet Strainer. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Replace the Fuel Pump Module. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 7. FUEL PUMP GROUND CIRCUIT OPEN OR HIGH RESISTANCE Turn the ignition off. Disconnect the Fuel Pump Module harness connector. Using a 12 volt test light connected to 12 volts, check the Fuel Pump Motor Ground circuit at the Fuel Pump Module harness connector. NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated and bright? Yes - Replace the Fuel Pump Module. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Repair the Fuel Pump Ground circuit for an open circuit or high resistance. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by manufacturer Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal Air Filter Element: Service and Repair Removal REMOVAL 1. Turn lock retainers (5) and remove fresh air inlet (2) from air cleaner housing (1). 2. Disconnect intake air temperature sensor connector (4). 3. Remove air inlet tube (5) from air cleaner housing (1). 4. Unfasten clasps (2) on sides of air cleaner housing cover. 5. Pull air cleaner cover (1) aside. 6. Remove filter element (3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal > Page 2413 7. If necessary, clean the inside of the air cleaner housing (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal > Page 2414 Air Filter Element: Service and Repair Installation INSTALLATION 1. Install new filter element. 2. Place cover over air cleaner housing. Snap clasps (2) in place. 3. Install air inlet tube (5). 4. Connect intake air temperature sensor connector (4). 5. Install fresh air inlet (2) on air cleaner housing (1) and lock retainers (5). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE PROCEDURE 1. Remove lower rear seat cushion. 2. Remove the fuel pump module cover. 3. Disconnect the electrical connector for fuel pump module. 4. Start and run engine until it stalls. 5. Attempt restarting engine until it will no longer run. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Page 2419 6. Turn ignition key to OFF position. 7. Disconnect negative battery cable. 8. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory. The scan tool must be used to erase a DTC. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications DESCRIPTION The 2.4 Liter (148 cu. in.) in-line four cylinder engine is a double over head camshaft design with mechanical lash tappets and four valves per cylinder design. This engine is NOT free-wheeling; meaning that the pistons will contact the valves in the event of a timing chain failure. The cylinders are numbered from front of the engine to the rear. The firing order is 1-3-4-2. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications SPARK PLUGS Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Removal Spark Plug: Service and Repair Removal 2.0/2.4L 1. Disconnect the negative battery cable. 2. Disconnect the electrical connectors from ignition coils. 3. Remove the ignition coil mounting bolt. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Removal > Page 2428 4. Twist the ignition coil then pull straight up. 5. Remove the spark plug using a quality socket with a rubber or foam insert. 6. Inspect the spark plug condition. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Removal > Page 2429 Spark Plug: Service and Repair Installation 2.0/2.4L Special care should be used when installing spark plugs in the cylinder head spark plug wells. Be sure the plugs do not drop into the wells, damage to the electrodes can occur. Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap. Overtightening can also damage the cylinder head. 1. To avoid cross threading, start the spark plug into the cylinder head by hand. 2. Tighten spark plugs to 17.5±2 Nm (13±2 ft. lbs.). 3. Install ignition coil on to spark plug. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Removal > Page 2430 4. Tighten coil mounting bolt. Tighten to 9 Nm (79.5 in. lbs.). 5. Connect electrical connectors and lock. 6. Connect the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Pressure Metric ................................................................................................................................................... ...................................................... 1172-1551 kPa Standard .............................................................. ............................................................................................................................................ 170-225 psi Compression should not be less than 1034 kPa (150 psi) and not vary more than 25 percent from cylinder to cylinder. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2434 Compression Check: Testing and Inspection CYLINDER COMPRESSION PRESSURE TEST The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine reaches normal operating temperature. Select a route free from traffic and other forms of congestion, observe all traffic laws, and accelerate through the gears several times briskly. 3. Remove engine cover. 4. Disconnect coil electrical connectors and remove coils. 5. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing indicators fouled, hot, oily, etc. Record cylinder number of spark plug for future reference. 6. Disconnect injector electrical connectors. 7. Be sure throttle blade is fully open during the compression check. 8. Insert compression gauge adaptor 8116 or the equivalent, into the #1 spark plug hole in cylinder head. Connect the 0-500 psi (Blue) pressure transducer CH7059 with cable adaptors to the DRBIII(R). 9. Crank engine until maximum pressure is reached on gauge. Record this pressure as #1 cylinder pressure. 10. Repeat the previous step for all remaining cylinders. 11. Compression should not be less than 1034 kPa (150 psi) and not vary more than 25 percent from cylinder to cylinder. 12. If one or more cylinders have abnormally low compression pressures, repeat the compression test. 13. If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem in the cylinder in question. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Valve Lash Intake ................................................................................................................................................... .............................. 17 - 23 mm (0.006 - 0.009 in.) Exhaust ................................................................ .............................................................................................................. 27 - 33 mm (0.010 - 0.012 in.) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 2438 Valve Clearance: Adjustments MEASURING VALVE LASH 1. Remove engine cover. 2. Remove cylinder head cover. 3. Rotate camshaft so lobes are vertical (1). 4. Check clearance using feeler gauges. 5. Repeat for all tappets and record readings. 6. If clearance was too small, go to the clearance to small procedure.Clearance to Small. 7. If clearance was too large, go to the clearance to large procedure.Clearance to Large. Clearance to Small Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 2439 1. Remove camshafts. 2. Specification - clearance = change 3. Decrease bucket thickness by change figure. 4. Install camshafts. 5. Verify that valve lash is correct. Clearance to Large 1. Remove camshafts. 2. Clearance - specification = change. 3. Increase bucket thickness by change figure. 4. Install camshafts. 5. Verify that valve lash is correct. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications Water pump Install mounting bolts (2). Tighten bolts to ...................................................................................................................................... 24 Nm (212 in. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Description and Operation > Water Pump Water Pump: Description and Operation Water Pump GAS ENGINE The water pump (3) on the world engine is attached to the water pump adapter on the front of the cylinder block. The water pump is driven by the accessory drive belt. The water pump is connected to the water plenum by the return tube. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Description and Operation > Water Pump > Page 2445 Water Pump: Description and Operation Pump-Water DESCRIPTION The water pump on this vehicle is attached to the front of the cylinder block. The water pump is driven by the timing belt. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Description and Operation > Page 2446 Water Pump: Testing and Inspection WATER PUMP A quick flow test to determine if the water pump is working effectively is to check heater system for proper operation. A defective pump will not provide an adequate flow of heated coolant through the system. WARNING: DO NOT REMOVE THE COOLING SYSTEM PRESSURE CAP WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR. Another flow test to help determine water pump operation is as follows: 1. Remove cooling system pressure cap. 2. Remove a small amount of coolant from the system. 3. Start the engine and warm up until thermostat opens. 4. With the thermostat open and coolant level low, visually inspect for coolant flow. If flow is present, the water pump is pumping coolant through the system. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Procedures Water Pump: Procedures INSPECTION Replace water pump body assembly if it has any of these defects: - Cracks or damage on the body. - Coolant leaks from the shaft seal, evident by wet coolant traces on the pump body. - Loose or rough turning bearing. - Impeller rubs either the pump body or the engine block. - Impeller loose or damaged. - Sprocket or sprocket flange loose or damaged. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Procedures > Page 2449 Water Pump: Removal and Replacement Removal GAS ENGINE 1. Remove the accessory drive belt. 2. Drain engine coolant. 3. Raise vehicle. 4. Remove accessory drive belt splash shield. 5. Drain cooling system. 6. Remove screws attaching water pump pulley (1). Remove pulley (1). 7. Remove water pump mounting bolts (2). 8. Remove water pump (3). Installation GAS ENGINE 1. Position water pump assembly (3) into water pump housing (4). 2. Install mounting bolts (2). Tighten bolts to 24 Nm (212 in. lbs.). 3. Install water pump pulley (1). Tighten bolts to 9 Nm (79 in lbs.). 4. Install drive belt splash shield. 5. Lower vehicle. 6. Install accessory drive belt. 7. Connect battery negative terminal. 8. Fill cooling system (Refer to COOLING - STANDARD PROCEDURE FILLING COOLING SYSTEM). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component Information > Technical Service Bulletins > Customer Interest for Thermostat Bypass Hose: > 07-003-06 > Sep > 06 > Cooling System - High Pitched Noise From Under Hood Thermostat Bypass Hose: Customer Interest Cooling System - High Pitched Noise From Under Hood NUMBER: 07-003-06 GROUP: Cooling DATE: September 21, 2006 SUBJECT: High Pitched Tone from Engine Compartment At Temperatures Below Zero Degrees F (-18C) OVERVIEW: This bulletin involves the installation of a new bypass valve and four 0-rings on the back of the radiator. MODELS: 2007 (PM) Caliber NOTE: This bulletin applies to vehicles built before April 27, 2006 (MDH 0427XX). SYMPTOM/CONDITION: The customer may experience a high frequency sound from the engine compartment at temperatures below 0° F (-18° C) while the bypass valve is operating. This will be more noticeable at continuous speeds over 25 mph when the bypass valve has full flow. DIAGNOSIS: If the customer experiences the Symptom/Condition perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove the battery following the procedures outlined in TechCONNECT. Refer to 8 Electrical/Battery System/Battery - Removal. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component Information > Technical Service Bulletins > Customer Interest for Thermostat Bypass Hose: > 07-003-06 > Sep > 06 > Cooling System - High Pitched Noise From Under Hood > Page 2459 2. Remove the four lines attached to the bypass valve (Fig. 1). NOTE: Discard the 0-rings on each of the lines. The new bypass valve comes with four 0-rings. 3. Remove the screw attaching the bypass valve to the Radiator (Fig. 1). 4. Install the new bypass valve (p/n 68021179AA) to back of radiator. Tighten screw to 5.1 N.m (45 In. Lbs.) 5. Replace the four 0-rings on the lines. 6. Install four lines to bypass valve and tighten lines to 18 N.m +/- 2 N.m (13.2 Ft. Lbs.) 7. Install the battery following the procedures outlined in TechCONNECT. Refer to 8 Electrical/Battery System/Battery - Install. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Thermostat Bypass Hose: > 07-003-06 > Sep > 06 > Cooling System - High Pitched Noise From Under Hood Thermostat Bypass Hose: All Technical Service Bulletins Cooling System - High Pitched Noise From Under Hood NUMBER: 07-003-06 GROUP: Cooling DATE: September 21, 2006 SUBJECT: High Pitched Tone from Engine Compartment At Temperatures Below Zero Degrees F (-18C) OVERVIEW: This bulletin involves the installation of a new bypass valve and four 0-rings on the back of the radiator. MODELS: 2007 (PM) Caliber NOTE: This bulletin applies to vehicles built before April 27, 2006 (MDH 0427XX). SYMPTOM/CONDITION: The customer may experience a high frequency sound from the engine compartment at temperatures below 0° F (-18° C) while the bypass valve is operating. This will be more noticeable at continuous speeds over 25 mph when the bypass valve has full flow. DIAGNOSIS: If the customer experiences the Symptom/Condition perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove the battery following the procedures outlined in TechCONNECT. Refer to 8 Electrical/Battery System/Battery - Removal. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Thermostat Bypass Hose: > 07-003-06 > Sep > 06 > Cooling System - High Pitched Noise From Under Hood > Page 2465 2. Remove the four lines attached to the bypass valve (Fig. 1). NOTE: Discard the 0-rings on each of the lines. The new bypass valve comes with four 0-rings. 3. Remove the screw attaching the bypass valve to the Radiator (Fig. 1). 4. Install the new bypass valve (p/n 68021179AA) to back of radiator. Tighten screw to 5.1 N.m (45 In. Lbs.) 5. Replace the four 0-rings on the lines. 6. Install four lines to bypass valve and tighten lines to 18 N.m +/- 2 N.m (13.2 Ft. Lbs.) 7. Install the battery following the procedures outlined in TechCONNECT. Refer to 8 Electrical/Battery System/Battery - Install. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Coolant: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2470 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Cooling System Fluid Capacity Engine Coolant .................................................................................................................................... ............................................... 7.2 Quarts (6.8 Liters) Note: Includes heater and coolant recovery bottled filled to MAX level. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 2473 Coolant: Fluid Type Specifications Cooling System Fluid Type Mopar Antifreeze/Coolant 5 year/100,000 mile formula HOAT (Hybrid Organic Additive Technology) or equivalent. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > Coolant Coolant: Description and Operation Coolant ENGINE COOLANT WARNING: Antifreeze is an ethylene glycol base coolant and is harmful if swallowed or inhaled. If swallowed, drink two glasses of water and induce vomiting. If inhaled, move to fresh air area, seek medical attention immediately. Do not store in open or unmarked containers. Wash skin and clothing thoroughly after coming in contact with ethylene glycol. Keep out of reach of children. Dispose of glycol base coolant properly, contact your dealer or government agency for location of collection center in your area. Do not open a cooling system when the engine is at operating temperature or hot under pressure, personal injury can result. Avoid radiator cooling fan when engine compartment related service is performed, personal injury can result. ETHYLENE-GLYCOL MIXTURES CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only Mopar(R) Antifreeze/Coolant, 5 year/100,000 Mile Formula (ethylene-glycol base coolant with corrosion inhibitors called HOAT, (Hybrid Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain a freeze point of -37° C (-35° F). The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle operating conditions. The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower than 44 percent, engine parts may be eroded by cavitation, and cooling system components may be severely damaged by corrosion. Maximum protection against freezing is provided with a 68% antifreeze concentration, which prevents freezing down to -67.7° C (-90° F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because the specific heat of antifreeze is lower than that of water. Use of 100 percent ethylene-glycol will cause formation of additive deposits in the system, as the corrosion inhibitive additives in ethylene-glycol require the presence of water to dissolve. The deposits act as insulation, causing temperatures to rise to as high as 149° C (300° F). This temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at 22° C (-8° F). PROPYLENE-GLYCOL MIXTURES It's overall effective temperature range is smaller than that of ethylene-glycol. The freeze point of 50/50 propylene-glycol and water is -32° C (-26° F). 5° C higher than ethylene-glycol's freeze point. The boiling point (protection against summer boil-over) of propylene-glycol is 125° C (257° F) at 96.5 kPa (14 psi), compared to 128° C (263° F) for ethylene-glycol. Use of propylene-glycol can result in boil-over or freeze-up on a cooling system designed for ethylene-glycol. Propylene glycol also has poorer heat transfer characteristics than ethylene glycol. This can increase cylinder head temperatures under certain conditions. Propylene-glycol/ethylene-glycol Mixtures can cause the destabilization of various corrosion inhibitors, causing damage to the various cooling system components. Also, once ethylene-glycol and propylene-glycol based coolants are mixed in the vehicle, conventional methods of determining freeze point will not be accurate. Both the refractive index and specific gravity differ between ethylene glycol and propylene glycol. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > Coolant > Page 2476 Coolant: Description and Operation Description HOAT COOLANT WARNING: Antifreeze is an ethylene-glycol base coolant and is harmful if swallowed or inhaled. If swallowed, drink two glasses of water and induce vomiting. If inhaled, move to fresh air area. Seek medical attention immediately. Do not store in open or unmarked containers. Wash skin and clothing thoroughly after coming in contact with ethylene-glycol. Keep out of reach of children. Dispose of glycol base coolant properly, contact your dealer or government agency for location of collection center in your area. Do not open a cooling system when the engine is at operating temperature or hot under pressure, personal injury can result. Avoid radiator cooling fan when engine compartment related service is performed, personal injury can result. CAUTION: Use of Propylene-Glycol based coolants is not recommended, as they provide less freeze protection and less corrosion protection. The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/fin radiator can transfer the heat to the air. The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Mopar(R) Antifreeze/Coolant, 5 Year/160.00 km, (100,000 Mile) Formula (MS-9769), or the equivalent ethylene-glycol base coolant with organic corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% ethylene-glycol and 50% distilled water to obtain a freeze point of -37° C (-35° F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. CAUTION: Mopar(R) Antifreeze/Coolant, 5 Year/160.00 km (100,000) Mile Formula (MS-9769) may not be mixed with any other type of antifreeze. Mixing of coolants other than specified (non-HOAT or other HOAT), may result in engine damage that may not be covered under the new vehicle warranty, and decreased corrosion protection. COOLANT PERFORMANCE The required ethylene-glycol (antifreeze) and water mixture depends upon climate and vehicle operating conditions. The coolant performance of various mixtures follows: Pure Water - Water can absorb more heat than a mixture of water and ethylene-glycol. This is for purpose of heat transfer only. Water also freezes at a higher temperature and allows corrosion. 100 percent Ethylene-Glycol - The corrosion inhibiting additives in ethylene-glycol need the presence of water to dissolve. Without water, additives form deposits in system. These act as insulation causing temperature to rise to as high as 149° C (300° F). This temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at -22° C (-8° F). 50/50 Ethylene-Glycol and Water - Is the recommended mixture, it provides protection against freezing to -37° C (-34° F). The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower, engine parts may be eroded by cavitation. Maximum protection against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing down to -67.7° C (-90° F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because specific heat of antifreeze is lower than that of water. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. COOLANT SELECTION AND ADDITIVES The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only Mopar(R) Antifreeze/Coolant, 5 Year/160.000 km (100,000 Mile) Formula (glycol base coolant with corrosion inhibitors called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain a freeze point of -37° C (-35° F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. CAUTION: Do not use coolant additives that are claimed to improve engine cooling. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > Coolant > Page 2477 Coolant: Description and Operation Operation OPERATION Coolant flows through the engine block absorbing the heat from the engine, then flows to the radiator where the cooling fins in the radiator transfers the heat from the coolant to the atmosphere. During cold weather the ethylene-glycol or propylene-glycol coolant prevents water present in the cooling system from freezing within temperatures indicated by mixture ratio of coolant to water. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Testing and Inspection > Coolant Concentration Testing Coolant: Testing and Inspection Coolant Concentration Testing COOLANT CONCENTRATION TESTING Coolant concentration should be checked when any additional coolant was added to system or after a coolant drain, flush and refill. The coolant mixture offers optimum engine cooling and protection against corrosion when mixed to a freeze point of -37° C (-34° F) to -46° C (-50° F). The use of a hydrometer or a refractometer can be used to test coolant concentration. A hydrometer will test the amount of glycol in a mixture by measuring the specific gravity of the mixture. The higher the concentration of ethylene glycol, the larger the number of balls that will float, and higher the freeze protection (up to a maximum of 60% by volume glycol). A refractometer Tool 8286 will test the amount of glycol in a coolant mixture by measuring the amount a beam of light bends as it passes through the fluid. Some coolant manufactures use other types of glycols into their coolant formulations. Propylene glycol is the most common new coolant. However, propylene glycol based coolants do not provide the same freezing protection and corrosion protection and is not recommended. CAUTION: Do not mix types of coolant corrosion protection will be severely reduced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Testing and Inspection > Coolant Concentration Testing > Page 2480 Coolant: Testing and Inspection Coolant Level Check COOLANT LEVEL CHECK NOTE: Do not remove pressure cap for routine coolant level inspections. The coolant recovery/reserve system provides a quick visual method for determining the coolant level without removing the radiator cap. Simply observe, with the engine idling and warmed up to normal operating temperature, that the level of the coolant in the recovery/reserve container is between the FULL HOT and ADD marks. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Removal Coolant Line/Hose: Service and Repair Removal REMOVAL The water pump inlet tube (2) connects the water pump to the coolant adapter. This tube is sealed by an O-ring and held in place by fasteners to the water pump housing. 1. Drain cooling system. 2. Remove the coolant adapter and secondary thermostat. 3. Raise and support vehicle. 4. Remove inlet tube mounting nuts (1). 5. Remove inlet tube (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Removal > Page 2485 Coolant Line/Hose: Service and Repair Installation INSTALLATION 1. Inspect the O-ring for damage before installing the tube. Replace O-ring as necessary. 2. Lubricate O-rings with soapy water. 3. Install new water inlet gasket between tube and water pump housing (2). 4. Position water pump inlet tube (3) on water pump housing (2). Hand tighten nuts to aide in tube alignment. 5. Install secondary thermostat and coolant adapter. 6. Tighten coolant tube nuts (1) to 24 Nm (212 in. lbs.). 7. Fill cooling system. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Description and Operation > Description Coolant Reservoir: Description and Operation Description GAS ENGINE The coolant recovery system consists of a coolant recovery container mounted to the RH inner wheel housing, a vent hose for the coolant recovery container, a hose connecting the container to the radiator neck, and a pressure cap. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Description and Operation > Description > Page 2490 Coolant Reservoir: Description and Operation Operation GAS ENGINE The system works in conjunction with the cooling system pressure cap to utilize thermal expansion and contraction of the coolant to keep the coolant free of trapped air. The system provides space for expansion and contraction. Also, the system provides a convenient and safe method for checking and adjusting the coolant level at atmospheric pressure without removing the pressure cap. It also provides some reserve coolant to compensate for minor leaks and evaporation or boiling losses. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Removal Coolant Reservoir: Service and Repair Removal GAS ENGINE 1. Siphon coolant from coolant recovery container. 2. Remove return hose (5) from upper radiator hose tee (3). 3. Remove coolant recovery bottle mount bolt (2). 4. Disengage coolant recovery container (6) from washer reservoir bottle (4). 5. Remove coolant recovery container and drain. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Removal > Page 2493 Coolant Reservoir: Service and Repair Installation GAS ENGINE 1. Engage coolant recovery container (6) into washer fluid reservoir (4). 2. Install coolant recovery container mounting bolt (2) and tighten to 4 Nm (35 in. lbs.). 3. Connect hose (5) at upper radiator Tee (3). 4. Fill coolant recovery container to proper level. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Locations Radiator Cooling Fan Motor: Locations Component ID: 52 Component : FAN MODULE-RADIATOR COOLING Connector: Name : FAN MODULE-RADIATOR COOLING C1 Color : BLACK # of pins : 2 A SERIES/PARALLEL RAD FAN RELAY FEED N210 12DB/DG B LOW/HIGH RAD FAN RELAY OUTPUT N23 12DB/GY Component Location - 7 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Locations > Page 2498 Connector: Name : FAN MODULE-RADIATOR COOLING C2 Color : BLACK # of pins : 2 A GROUND Z904 12BK/LG B RAD FAN RELAY OUTPUT N24 12DG/DB Component Location - 7 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Locations > Page 2499 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Motor: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: Provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2502 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2503 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2504 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2505 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2506 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2507 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2508 5. Release the Secondary Terminal Lock, if required (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2509 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2510 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2511 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2512 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2513 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2514 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2515 Radiator Cooling Fan Motor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2516 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2517 STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2518 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2519 Radiator Cooling Fan Motor: Connector Views Component ID: 52 Component : FAN MODULE-RADIATOR COOLING Connector: Name : FAN MODULE-RADIATOR COOLING C1 Color : BLACK # of pins : 2 A SERIES/PARALLEL RAD FAN RELAY FEED N210 12DB/DG B LOW/HIGH RAD FAN RELAY OUTPUT N23 12DB/GY Component Location - 7 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2520 Connector: Name : FAN MODULE-RADIATOR COOLING C2 Color : BLACK # of pins : 2 A GROUND Z904 12BK/LG B RAD FAN RELAY OUTPUT N24 12DG/DB Component Location - 7 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2521 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Radiator Fan Relays are located in the Fuse/Relay block. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Relay-Radiator Fan-Low/High Radiator Cooling Fan Motor Relay: Diagrams Relay-Radiator Fan-Low/High Component ID: 183 Component : RELAY-RADIATOR FAN-LOW/HIGH Connector: Name : RELAY-RADIATOR FAN-LOW/HIGH Color : # of pins : 0 A1 FUSED B(+) A16 12RD/BR A2 LOW/HIGH RAD FAN RELAY OUTPUT N23 12DB/GY A3 - A4 FUSED B(+) A16 12RD/BR A5 LOW/HIGH RAD FAN RELAY CONTROL N201 20DB/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Relay-Radiator Fan-Low/High > Page 2527 Radiator Cooling Fan Motor Relay: Diagrams Relay-Radiator Fan-Medium/High Component ID: 184 Component : RELAY-RADIATOR FAN-MEDIUM/HIGH Connector: Name : RELAY-RADIATOR FAN-MEDIUM/HIGH Color : # of pins : 0 C1 FUSED B(+) A16 12RD/BR C2 RAD FAN RELAY OUTPUT N24 12DG/DB C3 - C4 FUSED B(+) A16 12RD/BR C5 RAD FAN RELAY CONTROL N112 20DB/OR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Relay-Radiator Fan-Low/High > Page 2528 Radiator Cooling Fan Motor Relay: Diagrams Relay-Radiator Fan-Series/Parallel Component ID: 185 Component : RELAY-RADIATOR FAN-SERIES/PARALLEL Connector: Name : RELAY-RADIATOR FAN-SERIES/PARALLEL Color : # of pins : 0 B1 FUSED B(+) A16 12RD/BR B2 GROUND Z901 16BK B3 RAD FAN RELAY OUTPUT N24 12DG/DB B4 SERIES/PARALLEL RAD FAN RELAY FEED N210 12DB/DG B5 RAD FAN RELAY CONTROL N112 20DB/OR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor Coolant Temperature Sensor/Switch (For Computer): Technical Service Bulletins Engine Controls MIL On/DTC P0116/ECT Sensor NUMBER: 18-039-06 GROUP: Vehicle Performance DATE: December 6, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES FOR StarSCAN. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 7.02 SP2 OR HIGHER FOR THIS BULLETIN. SUBJECT: Flash: MIL Illumination DTC P0116 - Engine Coolant Temperature Sensor Performance OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) and the Transmission Control Module (1CM) with new software. CAUTION: VEHICLES EQUIPPED WITH A CVT TRANSMISSION MUST HAVE THE TRANSMISSION CONTROL MODULE (TCM) CHECKED FOR THE LATEST SOFTWARE LEVEL WHENEVER THE PCM SOFTWARE IS UPGRADED. IF NEWER TCM SOFTWARE IS AVAILABLE, IT MUST BE INSTALLED. MODELS: 2007 (PM) Caliber 2007 (MK49) Compass NOTE: This bulletin applies to PM/MK models equipped with a 1.8L, 2.0L or 2.4L gasoline engine (Sales Code EBA, ECN or ED3) and block heater (Sales Code NHK) built before November 20, 2006 (MDH 1120XX). NOTE: If an aftermarket or MOPAR accessory block heater is installed, the same conditions may apply. SYMPTOM/CONDITION: Some customers may experience MIL illumination after using the block heater. No other symptoms will be experienced. The technician may find the following DTC's: ^ P0116 - ENGINE COOLANT TEMPERATURE SENSOR PERFORMANCE DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If MIL illumination with DTC P0116 is present, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 2534 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING **STEP 5n and/or 8h**. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 7.02 SP2 software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. PM/MK Models equipped with a CVT must have the TCM reprogrammed as follows: 6. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. 7. Is the TCM part number recorded in step 6e above, the same as the new p/n shown on the "Flash File List" screen? a. Yes >> No further action is necessary. Proceed to Step 9. b. No >> the TCM will require flash reprogramming, proceed to Step 8. 8. Flash reprogram the TCM as follows: a. From the "Flash File List" screen, select "Download to Scantool". b. Select "Close" after the download is complete, then select "Back". c. Highlight the listed calibration. d. Select "Update Controller". Follow on screen instructions. e. When the update is complete, select "OK". f. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. g. Turn the ignition switch to the OFF position for no less than 15 seconds. h. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 2535 CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the TCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. ** NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 9. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Sensor-Engine Coolant Temperature 1 Coolant Temperature Sensor/Switch (For Computer): Locations Sensor-Engine Coolant Temperature 1 Component ID: 290 Component : SENSOR-ENGINE COOLANT TEMPERATURE 1 Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE 1 Color : DK. GRAY # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 SENSOR GROUND K900 20DB/DG 2 ECT 1 SIGNAL K2 20VT/OR Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Sensor-Engine Coolant Temperature 1 > Page 2538 Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Sensor-Engine Coolant Temperature 1 > Page 2539 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Sensor-Engine Coolant Temperature 1 > Page 2540 Coolant Temperature Sensor/Switch (For Computer): Locations Sensor-Engine Coolant Temperature 2 Component ID: 291 Component : SENSOR-ENGINE COOLANT TEMPERATURE 2 Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE 2 Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 SENSOR GROUND K915 20BR/WT 2 ECT 2 SIGNAL K222 20BR/YL Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Sensor-Engine Coolant Temperature 1 > Page 2541 Component Location - 15 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Sensor-Engine Coolant Temperature 1 > Page 2542 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Sensor-Engine Coolant Temperature 1 Coolant Temperature Sensor/Switch (For Computer): Diagrams Sensor-Engine Coolant Temperature 1 Component ID: 290 Component : SENSOR-ENGINE COOLANT TEMPERATURE 1 Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE 1 Color : DK. GRAY # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 SENSOR GROUND K900 20DB/DG 2 ECT 1 SIGNAL K2 20VT/OR Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Sensor-Engine Coolant Temperature 1 > Page 2545 Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Sensor-Engine Coolant Temperature 1 > Page 2546 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Sensor-Engine Coolant Temperature 1 > Page 2547 Coolant Temperature Sensor/Switch (For Computer): Diagrams Sensor-Engine Coolant Temperature 2 Component ID: 291 Component : SENSOR-ENGINE COOLANT TEMPERATURE 2 Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE 2 Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 SENSOR GROUND K915 20BR/WT 2 ECT 2 SIGNAL K222 20BR/YL Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Sensor-Engine Coolant Temperature 1 > Page 2548 Component Location - 15 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Sensor-Engine Coolant Temperature 1 > Page 2549 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Description Heater Core: Description and Operation Description DESCRIPTION NOTE: LHD model shown. RHD model similar. The heater core (1) for the heating-A/C system is mounted within the HVAC air distribution housing, which is located behind the instrument panel. The heater core is a heat exchanger made of rows of tubes with fins and is positioned within the air distribution housing so that only the selected amount of air entering the housing passes through the heater core before it is distributed through the heating-A/C system ducts and outlets. One end of the heater core is fitted with a tank (2) that includes the fittings for the heater core tubes (3). The heater core can only be serviced by removing the HVAC housing from the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Description > Page 2554 Heater Core: Description and Operation Operation OPERATION Engine coolant is circulated through the heater hoses to the heater core at all times. As the coolant flows through the heater core, heat is removed from the engine and is transferred to the heater core tubes and fins. Air directed through the heater core picks up the heat from the heater core fins. The blend-air door allows control of the heater output air temperature by regulating the amount of air flowing through the heater core. The blower motor speed controls the volume of air flowing through the HVAC housing. The heater core cannot be repaired and it must be replaced if inoperative, leaking or damaged. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Installation Heater Core: Service and Repair Installation INSTALLATION NOTE: LHD model with A/C shown. RHD and heater-only models similar. 1. Carefully install the heater core (6) into the left side of the air distribution housing (5). 2. On RHD models, install the air distribution housing (5) onto the HVAC housing (9). 3. Install the retaining bracket (4) and screw (3) that secure the heater core tubes (8). Tighten the screw to 1.2 Nm (10 in. lbs.) 4. Install the flange (2) that secures the heater core tubes to the front of the HVAC housing. 5. Install the screw (10) that secures the flange to the HVAC housing. Tighten the screw to 1.2 Nm (10 in. lbs.). NOTE: If the foam seal for the flange is deformed or damaged, it must be replaced. 6. Install the foam seal (1) onto the flange. 7. Install the left side front floor duct. NOTE: If the heater core is being replaced, flush the cooling system. 8. Install the HVAC housing assembly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Installation > Page 2557 Heater Core: Service and Repair Removal REMOVAL NOTE: The HVAC housing assembly must be removed from vehicle for service of the heater core. NOTE: LHD model with A/C shown. RHD and heater-only models similar. 1. Remove the HVAC housing assembly and place it on a workbench. 2. Remove the left side front floor duct. NOTE: If the foam seal for the flange is deformed or damaged, it must be replaced. 3. Remove the foam seal (1) from the flange (2) located on the front of the HVAC housing (9). 4. Remove the screw (10) that secures the flange to the front of the HVAC housing and remove the flange. 5. Remove the screw (3) that secures the retaining bracket (4) for the heater core tubes (8) to the left side of the air distribution housing (5). 6. On RHD models, remove the air distribution housing from the HVAC housing. 7. Carefully pull the heater core (6) out of the driver side of the air distribution housing. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Radiator Drain Plug > Component Information > Service and Repair > Removal Radiator Drain Plug: Service and Repair Removal REMOVAL CAUTION: Use of pliers on draincock is not recommended. Damage may occur to radiator or draincock. NOTE: It is not necessary to remove draincock during a routine coolant drain. 1. Drain the cooling system. 2. Open the draincock (2) by turning it counterclockwise until it stops. 3. Turn the draincock (2) back (clockwise) 1/8 turn. 4. Pull the draincock (2) from the radiator tank (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Radiator Drain Plug > Component Information > Service and Repair > Removal > Page 2563 Radiator Drain Plug: Service and Repair Installation INSTALLATION 1. Align draincock stem to radiator tank opening. 2. Push draincock (2) into the radiator tank opening. 3. Tighten the draincock (2) by turning clockwise until it stops. 4. Fill the cooling system. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Description and Operation > Description Radiator Cap: Description and Operation Description GAS ENGINES The cooling system is equipped with a pressure cap that releases built up pressure, maintaining a range of 97-124 kPa (14-18 psi). There is also a vent valve (6) in the center of the cap. This valve also opens when coolant is cooling and contracting, allowing coolant to return to radiator from coolant recovery container by vacuum through connecting hose. If valve is stuck shut, the radiator hoses will be collapsed on cool down. Clean the vent valve to ensure proper sealing when boiling point is reached. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Description and Operation > Description > Page 2568 Radiator Cap: Description and Operation Operation GAS The pressure cap allows the cooling system to operate at higher than atmospheric pressure. The higher pressure raises the coolant boiling point; this allows increased radiator cooling capacity. The secondary gasket in the cap seals the filler neck and the primary gasket seals the cooling system so that vacuum can be maintained, allowing coolant to be drawn back into the radiator from the reserve container. A vent valve in the center of the cap will remain shut as long as the cooling system is pressurized. As the coolant cools, it contracts and creates a vacuum in cooling system. This causes the vacuum valve to open and coolant in reserve/overflow tank to be drawn through connecting hose into radiator. If the vacuum valve is stuck shut, or overflow hose is kinked, radiator hoses will collapse on cool-down. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Cap-Radiator Pressure Radiator Cap: Testing and Inspection Cap-Radiator Pressure RADIATOR PRESSURE CAP PRESSURE RELIEF TESTING WARNING: If vehicle has been run recently, wait 15 minutes before removing cap. Place a shop towel over the cap, and without pushing down, rotate it counterclockwise to the first stop. Allow fluids to escape through the overflow tube. When the system stops pushing coolant and steam into the coolant recovery container and pressure drops, push down on the cap and remove it completely. Squeezing the radiator inlet hose with a shop towel (to check pressure) before and after turning to the first stop is recommended. WARNING: The warning words "do not open hot" on the pressure cap is a safety precaution. When hot, the cooling system builds up pressure. To prevent scalding or other injury, the pressure cap should not be removed while the system is hot and/or under pressure. The pressure cap upper gasket to filler neck seal can be checked by removing the overflow hose at the radiator filler neck overflow nipple. Attach the radiator pressure tester to the filler neck overflow nipple, and pump air into the system. The pressure cap upper gasket should relieve pressure at 69-124 kPa (10-18 psi), and hold pressure at 55 kPa (8 psi) minimum. There is no need to remove the pressure cap at any time except for the following purposes: - Check and adjust coolant freeze point - Refill system with new coolant - Conducting service procedures - Checking for leaks Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Cap-Radiator Pressure > Page 2571 Radiator Cap: Testing and Inspection Radiator Pressure Cap Testing RADIATOR PRESSURE CAP TESTING Dip the pressure cap in water. Clean any deposits off the vent valve or its seat and apply cap to end of the Pressure Cap Test Adaptor that is included with the Cooling System Tester 7700. Working the plunger, bring the pressure to 104 kPa (15 psi) on the gauge. If the pressure cap fails to hold pressure of at least 97 kPa (14 psi), replace the pressure cap. CAUTION: The Cooling System Tester Tool is very sensitive to small air leaks that will not cause cooling system problems. A pressure cap that does not have a history of coolant loss should not be replaced just because it leaks slowly when tested with this tool. Add water to the tool. Turn tool upside down and recheck pressure cap to confirm that cap is bad. If the pressure cap tests properly while positioned on Cooling System Tester 7700, but will not hold pressure or vacuum when positioned on the filler neck. Inspect the filler neck and cap top gasket for irregularities that may prevent the cap from sealing properly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Service and Repair > Cleaning Radiator Cap: Service and Repair Cleaning CLEANING Use only a mild soap to clean the pressure cap. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Service and Repair > Cleaning > Page 2574 Radiator Cap: Service and Repair Inspection INSPECTION Hold the cap in your hand, top side up. The vent valve (6) at the bottom of the cap should not open. If the valve opens, replace the cap. If the rubber seal (5) has swollen, preventing the valve from opening, replace the cap. Hold the cleaned cap in your hand, upside down. If any light can be seen between vent valve (6) and the rubber seal (5), replace the cap. A replacement cap must be of the type designed for a full pressure coolant systems. This design ensures coolant return to the radiator. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Radiator Fan Relays are located in the Fuse/Relay block. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Relay-Radiator Fan-Low/High Radiator Cooling Fan Motor Relay: Diagrams Relay-Radiator Fan-Low/High Component ID: 183 Component : RELAY-RADIATOR FAN-LOW/HIGH Connector: Name : RELAY-RADIATOR FAN-LOW/HIGH Color : # of pins : 0 A1 FUSED B(+) A16 12RD/BR A2 LOW/HIGH RAD FAN RELAY OUTPUT N23 12DB/GY A3 - A4 FUSED B(+) A16 12RD/BR A5 LOW/HIGH RAD FAN RELAY CONTROL N201 20DB/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Relay-Radiator Fan-Low/High > Page 2581 Radiator Cooling Fan Motor Relay: Diagrams Relay-Radiator Fan-Medium/High Component ID: 184 Component : RELAY-RADIATOR FAN-MEDIUM/HIGH Connector: Name : RELAY-RADIATOR FAN-MEDIUM/HIGH Color : # of pins : 0 C1 FUSED B(+) A16 12RD/BR C2 RAD FAN RELAY OUTPUT N24 12DG/DB C3 - C4 FUSED B(+) A16 12RD/BR C5 RAD FAN RELAY CONTROL N112 20DB/OR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Relay-Radiator Fan-Low/High > Page 2582 Radiator Cooling Fan Motor Relay: Diagrams Relay-Radiator Fan-Series/Parallel Component ID: 185 Component : RELAY-RADIATOR FAN-SERIES/PARALLEL Connector: Name : RELAY-RADIATOR FAN-SERIES/PARALLEL Color : # of pins : 0 B1 FUSED B(+) A16 12RD/BR B2 GROUND Z901 16BK B3 RAD FAN RELAY OUTPUT N24 12DG/DB B4 SERIES/PARALLEL RAD FAN RELAY FEED N210 12DB/DG B5 RAD FAN RELAY CONTROL N112 20DB/OR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor Coolant Temperature Sensor/Switch (For Computer): Technical Service Bulletins Engine Controls MIL On/DTC P0116/ECT Sensor NUMBER: 18-039-06 GROUP: Vehicle Performance DATE: December 6, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES FOR StarSCAN. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 7.02 SP2 OR HIGHER FOR THIS BULLETIN. SUBJECT: Flash: MIL Illumination DTC P0116 - Engine Coolant Temperature Sensor Performance OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) and the Transmission Control Module (1CM) with new software. CAUTION: VEHICLES EQUIPPED WITH A CVT TRANSMISSION MUST HAVE THE TRANSMISSION CONTROL MODULE (TCM) CHECKED FOR THE LATEST SOFTWARE LEVEL WHENEVER THE PCM SOFTWARE IS UPGRADED. IF NEWER TCM SOFTWARE IS AVAILABLE, IT MUST BE INSTALLED. MODELS: 2007 (PM) Caliber 2007 (MK49) Compass NOTE: This bulletin applies to PM/MK models equipped with a 1.8L, 2.0L or 2.4L gasoline engine (Sales Code EBA, ECN or ED3) and block heater (Sales Code NHK) built before November 20, 2006 (MDH 1120XX). NOTE: If an aftermarket or MOPAR accessory block heater is installed, the same conditions may apply. SYMPTOM/CONDITION: Some customers may experience MIL illumination after using the block heater. No other symptoms will be experienced. The technician may find the following DTC's: ^ P0116 - ENGINE COOLANT TEMPERATURE SENSOR PERFORMANCE DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If MIL illumination with DTC P0116 is present, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 2589 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING **STEP 5n and/or 8h**. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 7.02 SP2 software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. PM/MK Models equipped with a CVT must have the TCM reprogrammed as follows: 6. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. 7. Is the TCM part number recorded in step 6e above, the same as the new p/n shown on the "Flash File List" screen? a. Yes >> No further action is necessary. Proceed to Step 9. b. No >> the TCM will require flash reprogramming, proceed to Step 8. 8. Flash reprogram the TCM as follows: a. From the "Flash File List" screen, select "Download to Scantool". b. Select "Close" after the download is complete, then select "Back". c. Highlight the listed calibration. d. Select "Update Controller". Follow on screen instructions. e. When the update is complete, select "OK". f. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. g. Turn the ignition switch to the OFF position for no less than 15 seconds. h. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 2590 CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the TCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. ** NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 9. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Sensor-Engine Coolant Temperature 1 Coolant Temperature Sensor/Switch (For Computer): Locations Sensor-Engine Coolant Temperature 1 Component ID: 290 Component : SENSOR-ENGINE COOLANT TEMPERATURE 1 Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE 1 Color : DK. GRAY # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 SENSOR GROUND K900 20DB/DG 2 ECT 1 SIGNAL K2 20VT/OR Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Sensor-Engine Coolant Temperature 1 > Page 2593 Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Sensor-Engine Coolant Temperature 1 > Page 2594 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Sensor-Engine Coolant Temperature 1 > Page 2595 Coolant Temperature Sensor/Switch (For Computer): Locations Sensor-Engine Coolant Temperature 2 Component ID: 291 Component : SENSOR-ENGINE COOLANT TEMPERATURE 2 Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE 2 Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 SENSOR GROUND K915 20BR/WT 2 ECT 2 SIGNAL K222 20BR/YL Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Sensor-Engine Coolant Temperature 1 > Page 2596 Component Location - 15 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Sensor-Engine Coolant Temperature 1 > Page 2597 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Sensor-Engine Coolant Temperature 1 Coolant Temperature Sensor/Switch (For Computer): Diagrams Sensor-Engine Coolant Temperature 1 Component ID: 290 Component : SENSOR-ENGINE COOLANT TEMPERATURE 1 Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE 1 Color : DK. GRAY # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 SENSOR GROUND K900 20DB/DG 2 ECT 1 SIGNAL K2 20VT/OR Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Sensor-Engine Coolant Temperature 1 > Page 2600 Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Sensor-Engine Coolant Temperature 1 > Page 2601 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Sensor-Engine Coolant Temperature 1 > Page 2602 Coolant Temperature Sensor/Switch (For Computer): Diagrams Sensor-Engine Coolant Temperature 2 Component ID: 291 Component : SENSOR-ENGINE COOLANT TEMPERATURE 2 Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE 2 Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 SENSOR GROUND K915 20BR/WT 2 ECT 2 SIGNAL K222 20BR/YL Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Sensor-Engine Coolant Temperature 1 > Page 2603 Component Location - 15 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Sensor-Engine Coolant Temperature 1 > Page 2604 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Description and Operation > Description Thermostat: Description and Operation Description DESCRIPTION The primary thermostat is located on the front of the water plenum in the thermostat housing/coolant inlet. The thermostat has an air bleed vent located on its flange. The air bleed vent (1) and the locator dimple on thermostat seal provide for proper positioning of thermostat in inlet housing. The secondary thermostat is located in the cylinder head under the water plenum. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Description and Operation > Description > Page 2609 Thermostat: Description and Operation Operation OPERATION When the Engine is cold and both the primary and secondary thermostats are closed. The coolant will circulate through the engine, heater system, and the bypass. The cooling system has no flow through the radiator As the engine warms up, the primary thermostat will start to open at 82° C (179° F). Coolant will start to flow through the radiator oil cooler and transmission cooler. Coolant will flow through the transmission oil cooler only when the primary thermostat is fully open. The primary thermostat will fully open at 95° C (203° F). The secondary thermostat will start to open at 95° C (203° F). This will increase the coolant flow through the cylinder block and cylinder head and the radiator. The secondary thermostat will fully open at 110° C (230° F). If the thermostat is stuck open or allows coolant leakage through it, the engine will not operate at the proper temperature for obtaining engine fuel efficiency, performance and emissions levels. If this condition occurs, a diagnostic trouble code will be set and a MIL light will be turned on. Refer to the Powertrain Diagnostic Procedures for further information and diagnostics provided. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Description and Operation > Page 2610 Thermostat: Testing and Inspection ENGINE COOLANT THERMOSTAT The thermostat is operated by a wax filled chamber (pellet) which is sealed.When heated coolant reaches a predetermined temperature the wax pellet expands enough to overcome the closing spring and water pump pressure, which forces the valve to open. Coolant leakage into the pellet will cause a thermostat to fail open. Do not attempt to free up a thermostat with a screwdriver. Thermostat diagnostics is included in Totally Integrated Power Module's (TIPM) programming for on-board diagnosis. The malfunction indicator light (MIL) will illuminate and a diagnostic trouble code (DTC) will be set when an "open too soon" condition occurs. Do not change a thermostat for lack of heater performance or temperature gauge position, unless a DTC is present. Thermostat failing shut is the normal long term mode of failure, and normally, only on high mileage vehicles. The temperature gauge will indicate this. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Service and Repair > Removal Thermostat: Service and Repair Removal Gas - Primary Thermostat GAS - PRIMARY THERMOSTAT 1. Partially drain cooling system. 2. Remove air filter housing. 3. Disconnect coolant hose (1) from inlet housing (2). 4. Remove inlet housing bolts (3). 5. Remove thermostat assembly, and clean sealing surfaces. Gas - Secondary Thermostat GAS - SECONDARY THERMOSTAT 1. Partially drain cooling system. 2. Remove air filter housing. 3. Disconnect coolant hoses (1) from rear of coolant adapter (2). 4. Remove radiator hose (3). 5. Remove radiator hose (4) from front of coolant adapter (2). 6. Remove coolant adapter mounting bolts. 7. Carefully slide coolant adapter off water pump inlet tube and remove coolant adapter (2) and secondary thermostat. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Service and Repair > Removal > Page 2613 Thermostat: Service and Repair Installation Gas - Primary Thermostat GAS - PRIMARY THERMOSTAT 1. Position thermostat into the water plenum, aligning air bleed with the location notch on inlet housing (2). 2. Install inlet housing (2) onto coolant adapter. Tighten bolts to 9 Nm (79 in. lbs.). 3. Connect coolant hose (1). 4. Install air filter housing. 5. Fill cooling system. Gas - Secondary Thermostat GAS - SECONDARY THERMOSTAT 1. Position thermostat into the cylinder head. 2. Inspect the water pump inlet tube O-rings for damage before installing the tube in the coolant adapter. Replace O-ring as necessary. 3. Lubricate O-rings with soapy water. 4. Position coolant adapter on water pump inlet tube and cylinder head. 5. Install coolant adapter mounting bolts. Tighten bolts to 18 Nm (159 in. lbs.). 6. Connect front coolant hose (1). 7. Connect two rear coolant hoses (1). 8. Connect radiator hose (3). 9. Install air filter housing. 10. Fill cooling system. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Turbocharger Coolant Line > Component Information > Service and Repair > Removal - Lines And Hoses Turbocharger Coolant Line: Service and Repair Removal - Lines And Hoses REMOVAL - LINES AND HOSES COOLANT SUPPLY LINE 1. Raise vehicle on hoist. 2. Drain cooling system. 3. Remove banjo bolt from coolant supply line at turbocharger. 4. Disconnect coolant supply line flared fitting from brass fitting at engine block. 5. Remove coolant supply line. COOLANT RETURN LINE Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Turbocharger Coolant Line > Component Information > Service and Repair > Removal - Lines And Hoses > Page 2618 1. Drain cooling system. 2. Remove air cleaner housing. 3. Disconnect Inlet Air Temperature (IAT) sensor connector. 4. Disconnect Throttle Inlet Pressure (TIP) hose from charge air cooler hose. 5. Loosen hose clamp at throttle body. 6. Disconnect charge air cooler hose from throttle body. Reposition charge air cooler hose. 7. Remove fastener securing coolant return line bracket to cylinder head cover stud. 8. Remove hose clamp from coolant return line at heater tube. Disconnect hose from heater tube. 9. Remove banjo bolt from coolant return line at turbocharger. 10. Remove coolant return line. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Turbocharger Coolant Line > Component Information > Service and Repair > Removal - Lines And Hoses > Page 2619 Turbocharger Coolant Line: Service and Repair Installation INSTALLATION COOLANT SUPPLY LINE 1. If brass fitting was removed from engine block, apply thread sealer to threads and install in engine block. Tighten brass fitting to 41 Nm (30 ft. lbs.). 2. Position coolant supply line to mounting location. 3. Install NEW washers (2) on banjo fitting of coolant supply line. Hand start banjo bolt. 4. Hand start flared fitting of coolant supply line. 5. Tighten banjo fitting bolt to 37 Nm (27 ft. lbs.). 6. Tighten flared fitting to 31 Nm (23 ft. lbs.). 7. Lower vehicle. 8. Fill cooling system. COOLANT RETURN LINE 1. Position coolant return line to mounting location. 2. Install NEW washers (2) onto banjo fitting of coolant return line. Hand start banjo bolt. 3. Install hose onto heater tube. Install hose clamp. 4. Tighten banjo fitting bolt to 37 Nm (27 ft. lbs.). 5. Install fastener securing coolant return line bracket to cylinder head cover stud. 6. Connect charge air cooler hose to throttle body. 7. Tighten hose clamp to 1.7 Nm (15 in. lbs.). 8. Connect Throttle Inlet Pressure (TIP) hose to charge air cooler hose. 9. Connect Inlet Air Temperature (IAT) sensor connector. 10. Install air cleaner housing. 11. Fill cooling system. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications Water pump Install mounting bolts (2). Tighten bolts to ...................................................................................................................................... 24 Nm (212 in. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Description and Operation > Water Pump Water Pump: Description and Operation Water Pump GAS ENGINE The water pump (3) on the world engine is attached to the water pump adapter on the front of the cylinder block. The water pump is driven by the accessory drive belt. The water pump is connected to the water plenum by the return tube. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Description and Operation > Water Pump > Page 2625 Water Pump: Description and Operation Pump-Water DESCRIPTION The water pump on this vehicle is attached to the front of the cylinder block. The water pump is driven by the timing belt. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Description and Operation > Page 2626 Water Pump: Testing and Inspection WATER PUMP A quick flow test to determine if the water pump is working effectively is to check heater system for proper operation. A defective pump will not provide an adequate flow of heated coolant through the system. WARNING: DO NOT REMOVE THE COOLING SYSTEM PRESSURE CAP WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR. Another flow test to help determine water pump operation is as follows: 1. Remove cooling system pressure cap. 2. Remove a small amount of coolant from the system. 3. Start the engine and warm up until thermostat opens. 4. With the thermostat open and coolant level low, visually inspect for coolant flow. If flow is present, the water pump is pumping coolant through the system. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Procedures Water Pump: Procedures INSPECTION Replace water pump body assembly if it has any of these defects: - Cracks or damage on the body. - Coolant leaks from the shaft seal, evident by wet coolant traces on the pump body. - Loose or rough turning bearing. - Impeller rubs either the pump body or the engine block. - Impeller loose or damaged. - Sprocket or sprocket flange loose or damaged. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Procedures > Page 2629 Water Pump: Removal and Replacement Removal GAS ENGINE 1. Remove the accessory drive belt. 2. Drain engine coolant. 3. Raise vehicle. 4. Remove accessory drive belt splash shield. 5. Drain cooling system. 6. Remove screws attaching water pump pulley (1). Remove pulley (1). 7. Remove water pump mounting bolts (2). 8. Remove water pump (3). Installation GAS ENGINE 1. Position water pump assembly (3) into water pump housing (4). 2. Install mounting bolts (2). Tighten bolts to 24 Nm (212 in. lbs.). 3. Install water pump pulley (1). Tighten bolts to 9 Nm (79 in lbs.). 4. Install drive belt splash shield. 5. Lower vehicle. 6. Install accessory drive belt. 7. Connect battery negative terminal. 8. Fill cooling system (Refer to COOLING - STANDARD PROCEDURE FILLING COOLING SYSTEM). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Catalytic Converter Catalytic Converter: Description and Operation Catalytic Converter DESCRIPTION The combination exhaust manifold/catalytic converter is attached to the intermediate pipe using fasteners and a gasket for sealing. WARNING: The normal operating temperature of the exhaust system is very high. Therefore, never work around or attempt to service any part of the exhaust system until it is cooled. Special care should be taken when working near the catalytic converter. The temperature of the converter rises to a high level after a short period of engine operation time. CAUTION: DO NOT remove spark plug wires from plugs or by any other means short out cylinders. Failure of the catalytic converter can occur due to a temperature increase caused by unburned fuel passing through the converter. The stainless steel catalytic converter body is designed to last the life of the vehicle. Excessive heat can result in bulging or other distortion, but excessive heat will not be the fault of the converter. If unburned fuel enters the converter, overheating may occur. If a converter is heat-damaged, correct the cause of the damage at the same time the converter is replaced. Also, inspect all other components of the exhaust system for heat damage. Unleaded gasoline must be used to avoid contaminating the catalyst core. FWD vehicles use a catalytic converter located after the exhaust manifold and before the I-Pipe/Muffler assembly. AWD vehicles use a maniverter and an under floor catalytic converter. The under floor catalytic converter is located between the maniverter and the I-Pipe/muffler assembly. Diesel engine vehicles use a catalytic converter located between the turbocharger and the I-Pipe/Muffler assembly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Catalytic Converter > Page 2635 Catalytic Converter: Description and Operation Converter-Catalytic OPERATION - GAS ENGINE The three-way catalytic converter simultaneously converts three exhaust emissions into harmless gases. Specifically, HC and CO emissions are converted into water (H2O) and carbon dioxide (CO2). Oxides of Nitrogen (NOx) are converted into Nitrogen (N) and Oxygen. The three-way catalyst is most efficient in converting HC, CO and NOx at the stoichiometric air fuel ratio of 14.7:1. The oxygen content in a catalyst is important for efficient conversion of exhaust gases. When a high oxygen content (lean) air/fuel ratio is present for an extended period, oxygen content in a catalyst can reach a maximum. When a rich air/fuel ratio is present for an extended period, the oxygen content in the catalyst can become totally depleted. When this occurs, the catalyst fails to convert the gases. This is known as catalyst "punch through." Catalyst operation is dependent on its ability to store and release the oxygen needed to complete the emissions-reducing chemical reactions. As a catalyst deteriorates, its ability to store oxygen is reduced. Since the catalyst's ability to store oxygen is somewhat related to proper operation, oxygen storage can be used as an indicator of catalyst performance. Refer to the appropriate Diagnostic Information for diagnosis of a catalyst related Diagnostic Trouble Code (DTC). The combustion reaction caused by the catalyst releases additional heat in the exhaust system, causing temperature increases in the area of the reactor under severe operating conditions. Such conditions can exist when the engine misfires or otherwise does not operate at peak efficiency. Do not remove spark plug wires from plugs or by any other means short out cylinders. Failure of the catalytic converter can occur due to temperature increases caused by unburned fuel passing through the converter. This deterioration of the catalyst core can result in excessively high emission levels, noise complaints, and exhaust restrictions. Unleaded gasoline must be used to avoid ruining the catalyst core. Do not allow engine to operate above 1200 RPM in neutral for extended periods over 5 minutes. This condition may result in excessive exhaust system/floor pan temperatures because of no air movement under the vehicle. The flex joint allows flexing as the engine moves, preventing breakage that could occur from the back-and-forth motion of a transverse mounted engine. CAUTION: Due to exterior physical similarities of some catalytic converters with pipe assemblies, extreme care should be taken with replacement parts. There are internal converter differences required in some parts of the country (particularly vehicles built for States with strict emission requirements) and between model years. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service and Repair > Procedures Catalytic Converter: Procedures INSPECTION WARNING: The normal operating temperature of the exhaust system is very high. Therefore, never attempt to service any part of the exhaust system until it is cooled. Special care should be taken when working near the catalytic converter. The temperature of the converter rises to a high level after a short period of engine operation time. Check catalytic converter for a flow restriction. Visually inspect the catalytic converter element by using a borescope or equivalent. Remove oxygen sensor(s) and insert borescope. If borescope is not available, remove converter and inspect element using a flashlight. Inspect element for cracked or melted substrate. NOTE: Before replacing a catalytic converter, determine the root cause of failure. Most catalytic converter failures are caused by air, fuel or ignition problems. (Refer to Appropriate Diagnostic Information) for test procedures. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service and Repair > Procedures > Page 2638 Catalytic Converter: Removal and Replacement Under Floor Catalytic Converter UNDER FLOOR CATALYTIC CONVERTER WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER WORK AROUND OR ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATING TIME. 1. Raise vehicle on hoist and apply penetrating oil to band clamp fastener of component being removed. NOTE: Do not use petroleum-based lubricants when removing/installing muffler or exhaust pipe isolators as it may compromise the life of the part. A suitable substitute is a mixture of liquid dish soap and water. 2. Remove I-Pipe/Muffler assembly. 3. Disconnect oxygen sensor electrical connectors. NOTE: If spherical gasket is to be reused, mark orientation. 4. Remove flange bolts (3), springs and spherical gasket. 5. Remove under floor catalytic converter (4) from combination manifold/catalytic converter assembly (1). 6. Clean ends of pipes to assure mating of all parts. Discard broken or worn isolators, rusted or overused clamps, supports, and attaching parts. NOTE: When replacement is required on any component of the exhaust system, you must use original equipment parts (or their equivalent). Catalytic Converter - FWD CATALYTIC CONVERTER - FWD Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service and Repair > Procedures > Page 2639 WARNING: The normal operating temperature of the exhaust system is very high. Therefore, never attempt to service any part of the exhaust system until it is cooled. Special care should be taken when working near the catalytic converter. The temperature of the converter rises to a high level after a short period of engine operation time. NOTE: Before replacing a catalytic converter, determine the root cause of failure. Most catalytic converter failures are caused by air, fuel or ignition problems. Refer to the appropriate service diagnostic information for repair procedures. 1. Loosen intermediate pipe-to catalytic converter clamp. NOTE: Do not use petroleum-based lubricants when removing/installing muffler or exhaust pipe isolators as it may compromise the life of the part. A suitable substitute is a mixture of liquid dish soap and water. 2. Remove catalytic converter to exhaust manifold attaching fasteners and remove converter from vehicle. 3. Remove I-Pipe/Muffler assembly insulators as necessary to slide I-Pipe/Muffler assembly out of catalytic converter. 4. Remove and discard flange gasket. NOTE: When replacement is required on any component of the exhaust system, original equipment parts (or equivalent) must be used. Removal - Maniverter REMOVAL - MANIVERTER WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME. NOTE: Before replacing a catalytic converter, determine the root cause of failure. Most catalytic converter failures are caused by air, fuel or ignition problems. Refer to the appropriate service diagnostic information for repair procedures. 1. Remove under floor catalytic converter. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service and Repair > Procedures > Page 2640 NOTE: When replacement is required on any component of the exhaust system, original equipment parts (or equivalent) must be used. 2. Lower vehicle. 3. Remove secondary thermostat. 4. Remove maniverter mounting bolts. 5. Remove maniverter and gasket from the engine compartment. Under Floor Catalytic Converter UNDER FLOOR CATALYTIC CONVERTER When assembling exhaust system do not tighten clamps until components are aligned and clearances are checked. 1. Install under floor catalytic converter and the isolator supports to the underbody. 2. Position spherical gasket (2) with white side facing rear of vehicle, install springs, and bolts (3). Tighten bolts to 33 Nm (24 ft. lbs.). 3. Install I-Pipe/muffler assembly 4. Working from the front of system; align each component to maintain position and proper clearance with underbody parts. 5. Tighten band clamps to 55 Nm (40 ft. lbs.). CAUTION: Band clamps should never be tightened such that the two sides of the clamps are bottomed out against the center hourglass shaped center block. Once this occurs, the clamp band has been stretched and has lost its clamping force and must be replaced. NOTE: Maintain proper clamp orientation when replacing with new clamp. 6. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary. 7. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed. Catalytic Converter - FWD CATALYTIC CONVERTER - FWD Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service and Repair > Procedures > Page 2641 1. Position catalytic converter into I-Pipe/muffler assembly. 2. Using new gasket position catalytic converter against exhaust manifold. 3. Install flange bolts. Tighten to 29 Nm (21 ft. lbs.). 4. Working from the front of system; align each component to maintain position and proper clearance with underbody parts. 5. Tighten band clamps to 55 Nm (40 ft. lbs.). CAUTION: Band clamps should never be tightened such that the two sides of the clamps are bottomed out against the center hourglass shaped center block. Once this occurs, the clamp has lost clamping force and must be replaced. 6. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary. 7. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed. Installation - Maniverter INSTALLATION - MANIVERTER NOTE: When assembling exhaust system do not tighten clamps until all components are aligned and clearances are checked. 1. Position maniverter (1) in vehicle. Use a new flange gasket. 2. Using new gasket, install maniverter (1) and mounting bolts. Tighten bolts to 28 Nm (250 in. lbs.). 3. Install secondary thermostat. 4. Install under floor catalytic converter. 5. Working from the front of system; align each component to maintain position and proper clearance with underbody parts. 6. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary. 7. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Exhaust Manifold-Bolts ........................................................................................................................ .................................................... 34 Nm (25 ft. lbs.) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures Exhaust Manifold: Procedures Cleaning CLEANING 1. Discard gasket (if equipped) and clean all surfaces of manifold and cylinder head. Inspection INSPECTION 1. Inspect manifold gasket surfaces for flatness with straight edge. Surface must be flat within 0.15 mm per 300 mm (0.006 in. per foot) of manifold length. 2. Inspect manifolds for cracks or distortion. Replace manifold as necessary. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures > Page 2647 Exhaust Manifold: Removal and Replacement Removal ALL WHEEL DRIVE (AWD) 1. Remove engine cover (1). 2. Remove clean air hose (5) and air cleaner housing (1). 3. Disconnect negative cable from battery (3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures > Page 2648 4. Remove oxygen sensor (2). 5. Remove upper heat shield attaching bolts (1). 6. Remove upper heat shield (3). 7. Raise vehicle. 8. Disconnect oxygen sensor (2) electrical connector. 9. Remove exhaust pipe to maniverter bolts (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures > Page 2649 10. Remove maniverter support bracket (2). 11. Remove lower exhaust maniverter heat shield. 12. Remove exhaust maniverter lower retaining fasteners. 13. Lower vehicle. 14. Remove coolant adapter (3). 15. Lower vehicle and remove the upper exhaust maniverter retaining fasteners. 16. Remove maniverter (1) from above/between the engine and cowl panel. 17. Remove and discard maniverter gasket. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures > Page 2650 Front Wheel Drive (FWD) FRONT WHEEL DRIVE (FWD) 1. Install a new exhaust manifold gasketDO NOT APPLY SEALER. 2. Tighten the exhaust manifold bolts to 34 Nm (25 ft. lbs.). 3. Install exhaust manifold heat shields. Tighten bolts to 12 Nm (105 in. lbs.). 4. Install exhaust manifold support bracket (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures > Page 2651 5. Install new catalytic converter gasket. 6. Install exhaust pipe to manifold (1). Tighten fasteners to 28 Nm (250 in. lbs.). 7. Connect oxygen sensor electrical connector (3). 8. Connect negative cable to battery (3). 9. Install engine cover (1). All Wheel Drive (AWD) ALL WHEEL DRIVE (AWD) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures > Page 2652 1. Install a new maniverter gasket. DO NOT APPLY SEALER. 2. Position maniverter (1) in place. Tighten fasteners, starting at center and progressing outward in both directions to 34 Nm (300 in. lbs.). Raise and lower vehicle for fastener access as necessary. Repeat tightening procedure until all fasteners are at specified torque. 3. Install coolant adapter (3). 4. Install maniverter heat shields (3). Tighten bolts (1) to 12 Nm (105 in. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures > Page 2653 5. Install maniverter (2) support bracket and tighten bolts (1). 6. Install exhaust pipe to maniverter bolts (1). Tighten bolts to 28 Nm (250 in. lbs.). 7. Install oxygen sensor (2) and connect electrical connector. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures > Page 2654 8. Install engine cover (1). 9. Install the air cleaner housing (1). 10. Connect cables on battery (3). 11. Position air cleaner inlet (2) and tighten retainers (5). 12. Top off the fluids. Removal FRONT WHEEL DRIVE (FWD) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures > Page 2655 1. Remove engine cover (1). 2. Disconnect negative cable from battery. 3. Remove bolts attaching upper heat shield. 4. Remove upper heat shield. 5. Disconnect exhaust pipe from manifold. 6. Remove manifold support bracket (2). 7. Remove exhaust manifold heat shield (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures > Page 2656 8. Disconnect oxygen sensor electrical connector. 9. Remove exhaust manifold retaining fasteners. 10. Remove and discard manifold gasket. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Service and Repair > Removal Exhaust Pipe/Muffler Hanger: Service and Repair Removal REMOVAL 1. Disconnect isolator from exhaust system component. 2. Remove screws attaching isolator bracket to underbody. 3. Remove isolator assembly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Service and Repair > Removal > Page 2661 Exhaust Pipe/Muffler Hanger: Service and Repair Installation INSTALLATION 1. Position isolator bracket to underbody and install attaching screws. Tighten bracket screws to frame rail to 8.5 Nm (75 in. lbs.) and bracket screws to the rear panel to 3.7 Nm (33 in. lbs.). 2. Connect isolator to exhaust system component. 3. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary. 4. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Description and Operation Heat Shield: Description and Operation DESCRIPTION Heat shields (1), are needed to protect both the vehicle and the environment from the high temperatures developed in the vicinity of the catalytic converter. CAUTION: Avoid application of rust prevention compounds or undercoating materials to exhaust system floor pan heat shield. Light over-spray near the edges is permitted. Application of coating will greatly reduce the efficiency of the heat shields resulting in excessive floor pan temperatures and objectionable fumes. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Removal Heat Shield: Service and Repair Removal REMOVAL 1. Raise vehicle on hoist. 2. Remove fasteners attaching heat shield. 3. Remove heat shield(s) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Removal > Page 2667 Heat Shield: Service and Repair Installation INSTALLATION 1. Position heat shield(s) to underbody. 2. Install heat shield fasteners. 3. Inspect heat shield to exhaust system clearances and adjust as necessary. 4. Lower vehicle. 5. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary. 6. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Removal Muffler: Service and Repair Removal REMOVAL WARNING: The normal operating temperature of the exhaust system is very high. Therefore, never work around or attempt to service any part of the exhaust system until it is cooled. Special care should be taken when working near the catalytic converter. The temperature of the converter rises to a high level after a short period of engine operating time. NOTE: When replacement is required on any component of the exhaust system, you must use original equipment parts (or their equivalent). 1. Raise vehicle on hoist and apply penetrating oil to band clamp nut and bolt of component being removed. NOTE: Do not use petroleum-based lubricants when removing/installing muffler or exhaust pipe isolators (3) as it may compromise the life of the part. A suitable substitute is a mixture of liquid dish soap and water. 2. Remove exhaust system ground strap (1) at rear of I-Pipe/Muffler assembly (2). 3. Loosen band clamp and remove support isolators (3) at I-Pipe/Muffler assembly (2). Remove I-Pipe/Muffler assembly (2) from catalytic converter . 4. Clean ends of pipes and muffler to assure mating of all parts. Discard broken or worn isolators, rusted or overused clamps, supports, and attaching parts. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Removal > Page 2672 Muffler: Service and Repair Installation INSTALLATION When assembling exhaust system do not tighten clamp until components are aligned and clearances are checked. 1. Install the I-Pipe/Muffler assembly to catalytic converter and the isolator supports to the underbody. 2. Working from the front of system; align each component to maintain position and proper clearance with underbody parts. Tighten band clamp to 55 Nm (40 ft. lbs.). CAUTION: Band clamps should never be tightened such that the two sides of the clamps are bottomed out against the center hourglass shaped center block. Once this occurs, the clamp band has been stretched and has lost its clamping force and must be replaced. To replace the band clamp; remove the nut and peel back the ends of the clamp until spot weld breaks. File or grind remaining weld material until pipe surface is smooth. NOTE: Maintain proper clamp orientation when replacing with new clamp. 3. Connect the exhaust system ground strap. 4. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary. 5. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor Engine Control Module: Technical Service Bulletins Engine Controls - MIL On/DTC P0116/ECT Sensor NUMBER: 18-039-06 GROUP: Vehicle Performance DATE: December 6, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES FOR StarSCAN. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 7.02 SP2 OR HIGHER FOR THIS BULLETIN. SUBJECT: Flash: MIL Illumination DTC P0116 - Engine Coolant Temperature Sensor Performance OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) and the Transmission Control Module (1CM) with new software. CAUTION: VEHICLES EQUIPPED WITH A CVT TRANSMISSION MUST HAVE THE TRANSMISSION CONTROL MODULE (TCM) CHECKED FOR THE LATEST SOFTWARE LEVEL WHENEVER THE PCM SOFTWARE IS UPGRADED. IF NEWER TCM SOFTWARE IS AVAILABLE, IT MUST BE INSTALLED. MODELS: 2007 (PM) Caliber 2007 (MK49) Compass NOTE: This bulletin applies to PM/MK models equipped with a 1.8L, 2.0L or 2.4L gasoline engine (Sales Code EBA, ECN or ED3) and block heater (Sales Code NHK) built before November 20, 2006 (MDH 1120XX). NOTE: If an aftermarket or MOPAR accessory block heater is installed, the same conditions may apply. SYMPTOM/CONDITION: Some customers may experience MIL illumination after using the block heater. No other symptoms will be experienced. The technician may find the following DTC's: ^ P0116 - ENGINE COOLANT TEMPERATURE SENSOR PERFORMANCE DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If MIL illumination with DTC P0116 is present, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 2680 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING **STEP 5n and/or 8h**. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 7.02 SP2 software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. PM/MK Models equipped with a CVT must have the TCM reprogrammed as follows: 6. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. 7. Is the TCM part number recorded in step 6e above, the same as the new p/n shown on the "Flash File List" screen? a. Yes >> No further action is necessary. Proceed to Step 9. b. No >> the TCM will require flash reprogramming, proceed to Step 8. 8. Flash reprogram the TCM as follows: a. From the "Flash File List" screen, select "Download to Scantool". b. Select "Close" after the download is complete, then select "Back". c. Highlight the listed calibration. d. Select "Update Controller". Follow on screen instructions. e. When the update is complete, select "OK". f. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. g. Turn the ignition switch to the OFF position for no less than 15 seconds. h. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 2681 CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the TCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. ** NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 9. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 2682 Engine Control Module: Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 2683 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 2684 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 2685 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2686 Engine Control Module: Locations Component ID: 160 Component : MODULE-POWERTRAIN CONTROL Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK # of pins : 58 Qualifier : (GAS) Pin Description Circuit 1 FUSED MAIN RELAY OUTPUT F342 14BR/DG 2 GROUND Z925 16BK/YL 3 FUSED MAIN RELAY OUTPUT F342 14BR/DG 4 GROUND Z925 16BK/YL 5-6-- 7 O2 1/2 HEATER CONTROL K299 20BR/RD 8-9-10 - 11 - 12 - 13 S/C SWITCH GROUND V937 20VT/BR 14 - 15 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 16 FUSED B(+) A931 20RD/WT 17 - 18 - 19 FUEL PUMP CONTROL K31 20BR 20 O2 1/2 RETURN K904 20DB/DG 21 O2 1/2 SIGNAL K141 20DB/YL 22 5 VOLT SUPPLY K858 20BR/GY 23 5 VOLT SUPPLY F856 20YL/PK 24 - 25 STARTER CONTROL T752 20DG/OR 26 S/C SIGNAL 2 V72 20OR/VT 27 S/C SIGNAL 1 V71 20VT/OR 28 - 29 - 30 SENSOR GROUND K914 20DB/PK 31 - 32 BRAKE SIGNAL 1 B15 20DG/WT 33 - 34 APP SENSOR GROUND 2 K400 20BR/VT Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2687 35 EVAP PURGE RETURN K70 20DB/BR 36 APP SENSOR GROUND 1 K167 20BR/YL 37 START ENABLE F963 20PK/DB 38 VEHICLE SPEED SIGNAL K75 20DB/OR 39 EVAP PURGE CONTROL K52 20DB/WT 40 - 41 CAN C BUS (+) D65 20WT/BK 42 - 43 - 44 - 45 - - 46 - 47 ESM SIGNAL K107 20VT/WT 48 APP SIGNAL 2 K29 20WT/BR 49 APP SIGNAL 1 K23 20BR/OR 50 CLUTCH INTERLOCK SIGNAL T141 20YL/RD 51 - 52 BRAKE SIGNAL 2 B16 20LB/DG 53 GEN SENSE A804 20RD/GY 54 CAN C BUS (-) D64 20WT/LB 55 - 56 - 57 - 58 MAIN RELAY CONTROL K51 20BR/LG Component Location - 8 Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2688 Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2689 Connector: Name : MODULE-POWERTRAIN CONTROL C2 Color : BLACK # of pins : 96 Qualifier : (GAS) Pin Description Circuit 1 ETC MOTOR (+) K124 20DB/GY 2-3-4-- Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2690 5-- 6 A/C COMPRESSOR CONTROL C27 20LB/WT 7-8 IAT SIGNAL K21 20BK/RD 9-10 - 11 ECT 2 SIGNAL K222 20BR/YL 12 - 13 - 14 - 15 - 16 - 17 - 18 - 19 - 20 - 21 INJECTOR 3 CONTROL K13 20BR/LB 22 INJECTOR 4 CONTROL K14 20BR/TN 23 INJECTOR 1 CONTROL K11 20YL/BR 24 INJECTOR 2 CONTROL K12 20BR/DB 25 ETC MOTOR (-) K126 20DB/LG 26 - 27 MFV CONTROL K601 20BR/VT 28 - 29 - 30 - 31 - 32 - 33 O2 1/1 SIGNAL K41 20BK/DG 34 - 35 - 36 O2 1/1 RETURN K902 20BR/DG 37 EOT SIGNAL G24 20VT/BR 38 CMP 1/2 SIGNAL K441 20DB/BR 39 - 40 - 41 5 VOLT SUPPLY F855 20PK/YL 42 5 VOLT SUPPLY K857 20BR/LG 43 - 44 - 45 - 46 - 47 - 48 - 49 O2 1/1 HEATER CONTROL K99 20BR/OR 50 - 51 GEN FIELD CONTROL K20 20BR/GY 52 - 53 - 54 - 55 - 56 - 57 CMP 1/1 SIGNAL K44 20DB 58 SENSOR GROUND K915 20BR/WT 59 - 60 - 61 - 62 TP SENSOR GROUND K922 20BR 63 TP SIGNAL 2 K122 20DG/BR 64 TP SIGNAL 1 K22 20OR/BR 65 KS RETURN K942 20WT/BR 66 - 67 - - 68 - 69 - 70 CMP 1/1 CONTROL K76 20LB/WT Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2691 71 - 72 CMP 1/2 CONTROL K276 20DB/WT 73 COIL 4 CONTROL K15 18GY/DB 74 COIL 3 CONTROL K18 18DB/OR 75 COIL 2 CONTROL K17 18DB/TN 76 COIL 1 CONTROL K19 18DG/LB 77 - 78 - 79 CKP SIGNAL K24 20LB/BR 80 - 81 - - 82 SENSOR GROUND K900 20DB/DG 83 ECT 1 SIGNAL K2 20VT/OR 84 MFV SIGNAL K602 20YL/DB 85 MAP SIGNAL K1 20VT/LB 86 EOP SIGNAL G6 20VT/GY 87 - 88 KS SIGNAL K42 20LG/DB 89 - 90 - 91 - 92 - 93 - 94 - 95 - 96 - Component Location - 8 Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2692 Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2693 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: Provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2696 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2697 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2698 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2699 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2700 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2701 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2702 5. Release the Secondary Terminal Lock, if required (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2703 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2704 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2705 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2706 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2707 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2708 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2709 Engine Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2710 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2711 STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2712 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2713 Engine Control Module: Connector Views Component ID: 160 Component : MODULE-POWERTRAIN CONTROL Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK # of pins : 58 Qualifier : (GAS) Pin Description Circuit 1 FUSED MAIN RELAY OUTPUT F342 14BR/DG 2 GROUND Z925 16BK/YL 3 FUSED MAIN RELAY OUTPUT F342 14BR/DG 4 GROUND Z925 16BK/YL 5-6-- 7 O2 1/2 HEATER CONTROL K299 20BR/RD 8-9-10 - 11 - 12 - 13 S/C SWITCH GROUND V937 20VT/BR 14 - 15 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 16 FUSED B(+) A931 20RD/WT 17 - 18 - 19 FUEL PUMP CONTROL K31 20BR 20 O2 1/2 RETURN K904 20DB/DG 21 O2 1/2 SIGNAL K141 20DB/YL 22 5 VOLT SUPPLY K858 20BR/GY 23 5 VOLT SUPPLY F856 20YL/PK 24 - 25 STARTER CONTROL T752 20DG/OR 26 S/C SIGNAL 2 V72 20OR/VT 27 S/C SIGNAL 1 V71 20VT/OR 28 - 29 - 30 SENSOR GROUND K914 20DB/PK 31 - 32 BRAKE SIGNAL 1 B15 20DG/WT 33 - 34 APP SENSOR GROUND 2 K400 20BR/VT Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2714 35 EVAP PURGE RETURN K70 20DB/BR 36 APP SENSOR GROUND 1 K167 20BR/YL 37 START ENABLE F963 20PK/DB 38 VEHICLE SPEED SIGNAL K75 20DB/OR 39 EVAP PURGE CONTROL K52 20DB/WT 40 - 41 CAN C BUS (+) D65 20WT/BK 42 - 43 - 44 - 45 - - 46 - 47 ESM SIGNAL K107 20VT/WT 48 APP SIGNAL 2 K29 20WT/BR 49 APP SIGNAL 1 K23 20BR/OR 50 CLUTCH INTERLOCK SIGNAL T141 20YL/RD 51 - 52 BRAKE SIGNAL 2 B16 20LB/DG 53 GEN SENSE A804 20RD/GY 54 CAN C BUS (-) D64 20WT/LB 55 - 56 - 57 - 58 MAIN RELAY CONTROL K51 20BR/LG Component Location - 8 Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2715 Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2716 Connector: Name : MODULE-POWERTRAIN CONTROL C2 Color : BLACK # of pins : 96 Qualifier : (GAS) Pin Description Circuit 1 ETC MOTOR (+) K124 20DB/GY 2-3-4-- Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2717 5-- 6 A/C COMPRESSOR CONTROL C27 20LB/WT 7-8 IAT SIGNAL K21 20BK/RD 9-10 - 11 ECT 2 SIGNAL K222 20BR/YL 12 - 13 - 14 - 15 - 16 - 17 - 18 - 19 - 20 - 21 INJECTOR 3 CONTROL K13 20BR/LB 22 INJECTOR 4 CONTROL K14 20BR/TN 23 INJECTOR 1 CONTROL K11 20YL/BR 24 INJECTOR 2 CONTROL K12 20BR/DB 25 ETC MOTOR (-) K126 20DB/LG 26 - 27 MFV CONTROL K601 20BR/VT 28 - 29 - 30 - 31 - 32 - 33 O2 1/1 SIGNAL K41 20BK/DG 34 - 35 - 36 O2 1/1 RETURN K902 20BR/DG 37 EOT SIGNAL G24 20VT/BR 38 CMP 1/2 SIGNAL K441 20DB/BR 39 - 40 - 41 5 VOLT SUPPLY F855 20PK/YL 42 5 VOLT SUPPLY K857 20BR/LG 43 - 44 - 45 - 46 - 47 - 48 - 49 O2 1/1 HEATER CONTROL K99 20BR/OR 50 - 51 GEN FIELD CONTROL K20 20BR/GY 52 - 53 - 54 - 55 - 56 - 57 CMP 1/1 SIGNAL K44 20DB 58 SENSOR GROUND K915 20BR/WT 59 - 60 - 61 - 62 TP SENSOR GROUND K922 20BR 63 TP SIGNAL 2 K122 20DG/BR 64 TP SIGNAL 1 K22 20OR/BR 65 KS RETURN K942 20WT/BR 66 - 67 - - 68 - 69 - 70 CMP 1/1 CONTROL K76 20LB/WT Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2718 71 - 72 CMP 1/2 CONTROL K276 20DB/WT 73 COIL 4 CONTROL K15 18GY/DB 74 COIL 3 CONTROL K18 18DB/OR 75 COIL 2 CONTROL K17 18DB/TN 76 COIL 1 CONTROL K19 18DG/LB 77 - 78 - 79 CKP SIGNAL K24 20LB/BR 80 - 81 - - 82 SENSOR GROUND K900 20DB/DG 83 ECT 1 SIGNAL K2 20VT/OR 84 MFV SIGNAL K602 20YL/DB 85 MAP SIGNAL K1 20VT/LB 86 EOP SIGNAL G6 20VT/GY 87 - 88 KS SIGNAL K42 20LG/DB 89 - 90 - 91 - 92 - 93 - 94 - 95 - 96 - Component Location - 8 Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2719 Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2720 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description Engine Control Module: Description and Operation Description PCM Ground PCM GROUND Ground is provided through multiple pins of the PCM connector. Depending on the vehicle there may be as many as two different ground pins. There are power grounds and sensor grounds. The power grounds are used to control the ground side relays, solenoids, ignition coil or injectors. The signal ground is used for any input that uses sensor return for ground, and the ground side of any internal processing component. The PCM case is shielded to prevent RFI and EMI. The PCM case is grounded and must be firmly attached to a good, clean body ground. Internally all grounds are connected together, however there is noise suppression on the sensor ground. For EMI and RFI protection the housing and cover are also grounded separately from the ground pins. Sensor Return - PCM Input SENSOR RETURN - PCM INPUT The sensor return circuit provides a low electrical noise ground reference for all of the systems sensors. The sensor return circuit connects to internal ground circuits within the Powertrain Control Module (PCM). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description > Page 2723 Engine Control Module: Description and Operation Operation Powertrain Control Module POWERTRAIN CONTROL MODULE The PCM receives input signals from various switches and sensors that are referred to as PCM Inputs. Based on these inputs, the PCM adjusts various engine and vehicle operations through devices that are referred to as PCM Outputs. NOTE: PCM Inputs: - Air Conditioning Controls - Battery Voltage - Brake Switch - Camshaft Position Sensor - Clutch Upstop Switch - Clutch Interlock - Crankshaft Position Sensor - Engine Coolant Temperature Sensor - Fuel Level Sensor (Bus message) - Ignition Switch - Intake Air Temperature Sensor - Knock Sensor - Evaporative System Integrity Monitor - Manifold Absolute Pressure (MAP) Sensor - Oil Pressure Switch - Oxygen Sensors - Power Steering Pressure Switch - Speed Control Switches - Vehicle Speed Sensor (MTX-equipped models) NOTE: PCM Outputs: - Air Conditioning Clutch Relay - Charging Indicator Lamp (Bus Message) - Proportional Purge Solenoid - Fuel Injectors - Generator Field - Ignition Coils - Malfunction Indicator (Check Engine) Lamp (Bus Message) - Manifold Flow Valve - Oxygen Sensors Heater Controls - Variable Valve Timing - Vehicle Speed (Manual Transmission) Based on inputs it receives, the PCM adjusts fuel injector pulse width, idle speed, ignition spark advance, ignition coil dwell and EVAP canister purge operation. The PCM also determines the appropriate transmission shift schedule and shift points, depending on the present operating conditions and driver demand. The PCM regulates the cooling fan, air conditioning and speed control systems. The PCM changes generator charge rate by adjusting the Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description > Page 2724 generator field. The PCM also performs diagnostics. The PCM adjusts injector pulse width (air-fuel ratio) based on the following inputs. - Battery voltage - Coolant temperature - Exhaust gas content (oxygen sensor) - Engine speed (crankshaft position sensor) - Intake air temperature - Manifold absolute pressure - Throttle position The PCM adjusts ignition timing based on the following inputs. - Coolant temperature - Engine speed (crankshaft position sensor) - Knock sensor - Manifold absolute pressure - Throttle position - Transmission gear selection (park/neutral switch) - Intake air temperature The PCM also adjusts engine idle speed through the idle air control motor based on the following inputs. - Air conditioning sense - Battery voltage - Brake switch - Coolant temperature - Engine speed (crankshaft position sensor) - Engine run time - Manifold absolute pressure - Power steering pressure switch - Throttle position - Transmission gear selection (park/neutral switch) - Vehicle distance (speed) The camshaft position sensor and crankshaft position sensor signals are sent to the PCM. If the PCM does not receive the signal within approximately 1 second of engine cranking, it deactivates the fuel pump. When these are deactivated, power is shut off to the fuel injectors, ignition coils, oxygen sensor heating elements and fuel pump. The PCM contains a voltage converter that changes battery voltage to a regulated 5 volt direct current to power the camshaft position sensor, crankshaft position sensor, manifold absolute pressure sensor, throttle position sensor, A/C pressure switch, A/C pressure transducer, and vehicle speed sensor. 5 Volt Supply - PCM Output 5 VOLT SUPPLY - PCM OUTPUT The PCM supplies 5 volts to the following sensors: - A/C pressure transducer - Ambient Temperature sensor - Battery temperature - Camshaft Position Sensor (NGC) - Crankshaft Position Sensor (NGC) - Engine coolant temperature sensor - Inlet Air Temperature Sensor - Knock sensor - Linear EGR solenoid (if equipped) - Manifold absolute pressure sensor - Oil Pressure Switch Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM/SKREEM Programming Engine Control Module: Testing and Inspection PCM/ECM/SKREEM Programming PCM/ECM/SKREEM PROGRAMMING NOTE: Before replacing the Powertrain Control Module (PCM) or Engine Control Module (ECM), be certain to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most PCM/ECM driver/control circuit failures are caused by internal component failures (i.e. relays and solenoids) and shorted circuits (i.e. pull-ups, drivers, and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has been set. When a PCM, or ECM, and the Sentry Key REmote Entry Module (SKREEM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: 1. Program the new PCM or ECM. 2. Program the new SKREEM (also sometimes referred to as the Wireless Control Module or WCM). 3. Replace all ignition keys and program them into the new SKREEM/WCM. PROGRAMMING THE SKREEM The SKIS Secret Key is an ID code that is unique to each SKREEM/WCM. This code is programmed and stored in the SKREEM/WCM, the PCM/ECM, and each ignition key transponder chip. When the PCM or SKREEM/WCM is replaced, it is necessary to program the Secret Key into the new module using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool for "PCM Replaced" or "WCM Replaced" under "Miscellaneous Functions" for the "WCM/Wireless Control Module" menu item as appropriate. NOTE: If the PCM/ECM and the SKREEM/WCM are replaced at the same time, all vehicle ignition keys will need to be replaced and new keys programmed into the new SKREEM/WCM. NOTE: Programming the PCM/ECM or SKREEM is done using a diagnostic scan tool and a PIN to enter secure access mode. If eight attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. (Ensure all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary). PROGRAMMING IGNITION KEYS TO THE SKREEM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKREEM/WCM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKREEM/WCM. To program ignition keys into the SKREEM/WCM, follow the programming steps outlined in the diagnostic scan tool for PROGRAM IGNITION KEYS OR KEY FOBS under MISCELLANEOUS FUNCTIONS for the WCM/WIRELESS CONTROL MODULE menu item. NOTE: A maximum of eight keys can be learned to each SKREEM. Once a key is learned to a SKREEM, that key has acquired the Secret Key for that SKREEM and cannot be transferred to any other SKREEM or vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: - Programming Not Attempted - The scan tool attempts to read the programmed key status and there are no keys programmed into SKREEM memory. - Programming Key Failed (Possible Used Key From Wrong Vehicle) - SKREEM is unable to program an ignition key transponder due to one of the following: - The ignition key transponder is faulty. - The ignition key transponder is or has been already programmed to another vehicle. - 8 Keys Already Learned, Programming Not Done - The SKREEM transponder ID memory is full. - Learned Key In Ignition - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKREEM memory. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM/SKREEM Programming > Page 2727 Engine Control Module: Testing and Inspection Pinion Factor Setting PINION FACTOR SETTING NOTE: This procedure must be performed if the PCM has been replaced with a NEW or replacement unit. Failure to perform this procedure will result in an inoperative or improperly calibrated speedometer. The vehicle speed readings for the speedometer are taken from the output speed sensor. The PCM must be calibrated to the different combinations of equipment (final drive and tires) available. Pinion Factor allows the technician to set the Powertrain Control Module initial setting so that the speedometer readings will be correct. To properly read and/or reset the Pinion Factor, it is necessary to use a scan tool. 1. Plug the scan tool into the diagnostic connector located under the instrument panel. 2. Select the Transmission menu. 3. Select the Miscellaneous menu. 4. Select Pinion Factor. Then follow the instructions on the scan tool screen. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal Engine Control Module: Service and Repair Removal REMOVAL USE THE SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM) WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (VIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. To avoid possible voltage spike damage to PCM, ignition key must be off, and negative battery cable must be disconnected before unplugging PCM connectors. 1. Disconnect negative battery cable. 2. Unlock and disconnect the electrical connectors from PCM. 3. Remove the air cleaner box. 4. Remove the three mounting bolts. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal > Page 2730 5. Tip module out and remove from bracket. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal > Page 2731 Engine Control Module: Service and Repair Installation INSTALLATION USE THE SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM) WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (VIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. 1. Tip module into bracket. 2. Install three mounting bolts and tighten to 9 Nm (80 in. lbs.) torque. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal > Page 2732 3. Check pins in electrical connectors for damage. Repair as necessary. 4. Connect electrical connectors and lock. 5. Install air cleaner box. 6. Connect negative battery cable. 7. Use the scan tool to reprogram new PCM with vehicles original Identification Number (VIN) and original vehicle mileage. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Main Relay is located in the Fuse/Relay block. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2736 Main Relay (Computer/Fuel System): Diagrams Component ID: 182 Component : RELAY-MAIN Connector: Name : RELAY-MAIN Color : # of pins : 0 B6 FUSED B(+) A14 12RD/YL B7 MAIN RELAY OUTPUT K542 12BR/WT B8 - B9 FUSED B(+) A14 12RD/YL B10 MAIN RELAY CONTROL K51 20BR/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Main Relay is located in the Fuse/Relay block. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2741 Main Relay (Computer/Fuel System): Diagrams Component ID: 182 Component : RELAY-MAIN Connector: Name : RELAY-MAIN Color : # of pins : 0 B6 FUSED B(+) A14 12RD/YL B7 MAIN RELAY OUTPUT K542 12BR/WT B8 - B9 FUSED B(+) A14 12RD/YL B10 MAIN RELAY CONTROL K51 20BR/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Component ID: 281 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 APP SIGNAL 2 K29 20WT/BR 2 APP SENSOR GROUND 2 K400 20BR/VT 3 5 VOLT SUPPLY K854 20VT/BR 3 5 VOLT SUPPLY K858 20BR/GY 4 APP SIGNAL 1 K23 20BR/OR 5 APP SENSOR GROUND 1 K167 20BR/YL 6 5 VOLT SUPPLY K852 20BR/VT 6 5 VOLT SUPPLY F856 20YL/PK Component Location - 44 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2747 Component Location - 47 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2748 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2749 Accelerator Pedal Position Sensor: Diagrams Component ID: 281 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 APP SIGNAL 2 K29 20WT/BR 2 APP SENSOR GROUND 2 K400 20BR/VT 3 5 VOLT SUPPLY K854 20VT/BR 3 5 VOLT SUPPLY K858 20BR/GY 4 APP SIGNAL 1 K23 20BR/OR 5 APP SENSOR GROUND 1 K167 20BR/YL 6 5 VOLT SUPPLY K852 20BR/VT 6 5 VOLT SUPPLY F856 20YL/PK Component Location - 44 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2750 Component Location - 47 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2751 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2752 Accelerator Pedal Position Sensor: Description and Operation DESCRIPTION The Accelerator Pedal Position Sensor (APPS) is a variable resistor that provides the PCM with an input signal (voltage). The signal represents pedal angle position. As the position of the accelerator pedal changes, the resistance of the APPS changes. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal Accelerator Pedal Position Sensor: Service and Repair Removal REMOVAL 1. Disconnect negative battery cable. 2. Disconnect the electrical connector from the module. 3. Remove the mounting nuts. 4. Remove assembly from the mounting studs. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal > Page 2755 Accelerator Pedal Position Sensor: Service and Repair Installation INSTALLATION 1. Install APPS module. 2. Tighten the mounting nuts. 3. Connect electrical connector. 4. Connect negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Sensor-Camshaft 1/1 Position Camshaft Position Sensor: Locations Sensor-Camshaft 1/1 Position Component ID: 284 Component : SENSOR-CAMSHAFT 1/1 POSITION Connector: Name : SENSOR-CAMSHAFT 1/1 POSITION Color : BLACK # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY K857 20BR/LG 2 SENSOR GROUND K900 20DB/DG 3 CMP 1/1 SIGNAL K44 20DB Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Sensor-Camshaft 1/1 Position > Page 2760 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Sensor-Camshaft 1/1 Position > Page 2761 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Sensor-Camshaft 1/1 Position > Page 2762 Camshaft Position Sensor: Locations Sensor-Camshaft 1/2 Position Component ID: 285 Component : SENSOR-CAMSHAFT 1/2 POSITION Connector: Name : SENSOR-CAMSHAFT 1/2 POSITION Color : BLACK # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K915 20BR/WT 3 CMP 1/2 SIGNAL K441 20DB/BR Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Sensor-Camshaft 1/1 Position > Page 2763 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Sensor-Camshaft 1/1 Position Camshaft Position Sensor: Diagrams Sensor-Camshaft 1/1 Position Component ID: 284 Component : SENSOR-CAMSHAFT 1/1 POSITION Connector: Name : SENSOR-CAMSHAFT 1/1 POSITION Color : BLACK # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY K857 20BR/LG 2 SENSOR GROUND K900 20DB/DG 3 CMP 1/1 SIGNAL K44 20DB Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Sensor-Camshaft 1/1 Position > Page 2766 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Sensor-Camshaft 1/1 Position > Page 2767 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Sensor-Camshaft 1/1 Position > Page 2768 Camshaft Position Sensor: Diagrams Sensor-Camshaft 1/2 Position Component ID: 285 Component : SENSOR-CAMSHAFT 1/2 POSITION Connector: Name : SENSOR-CAMSHAFT 1/2 POSITION Color : BLACK # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K915 20BR/WT 3 CMP 1/2 SIGNAL K441 20DB/BR Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Sensor-Camshaft 1/1 Position > Page 2769 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Description Camshaft Position Sensor: Description and Operation Description DESCRIPTION The camshaft position sensors are mounted to the front and rear of the cylinder head. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Description > Page 2772 Camshaft Position Sensor: Description and Operation Operation OPERATION The PCM sends approximately 5 volts to the Hall-effect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. The input to the PCM occurs on a 5 volt output reference circuit. A ground for the sensor is provided through the sensor return circuit. The PCM identifies camshaft position by registering the change from 5 to 0 volts, as signaled from the camshaft position sensor. The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Removal Camshaft Position Sensor: Service and Repair Removal Front Camshaft Position Sensor FRONT CAMSHAFT POSITION SENSOR 1. Remove the air cleaner hose to throttle body, disconnect the inlet air temperature sensor electrical connector. 2. Disconnect negative battery cable. 3. Disconnect electrical connector from camshaft position sensor. 4. Remove camshaft position sensor mounting screws. 5. Remove sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 2775 Rear Camshaft Position Sensor REAR CAMSHAFT POSITION SENSOR 1. Disconnect negative battery cable. 2. Disconnect electrical connector at sensor. 3. Remove nut retaining heat shield. 4. Pull heat shield out to uncover sensor. 5. Remove mounting bolt. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 2776 6. Remove sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 2777 Camshaft Position Sensor: Service and Repair Installation Front Camshaft Position Sensor FRONT CAMSHAFT POSITION SENSOR 1. Lubricate sensor O-ring. 2. Install camshaft position sensor utilizing twisting motion. Make sure sensor is fully seated. Do not drive sensor into the bore with screw. This can cause sensor to be incorrectly seated causing engine to fail. Tighten sensor mounting screws to 9 Nm (79.5 in. lbs.). 3. Carefully attach electrical connector to camshaft position sensor. Installation at an angle may damage the sensor pins. 4. Install the negative battery cable. 5. Install the air cleaner to throttle body hose, connect the inlet air temperature sensor electrical connector. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 2778 Rear Camshaft Position Sensor REAR CAMSHAFT POSITION SENSOR 1. Lubricate sensor O-ring. 2. Install sensor utilizing twisting motion. Make sure sensor is fully seated. Do not drive sensor into the bore with screw. This can cause sensor to be incorrectly seated causing engine to fail. 3. Install mounting bolt and tighten to 9 Nm (79.5 in. lbs.). 4. Carefully attach electrical connector to camshaft position sensor. Fill for positive lock (click). Installation at angle may damage the sensor pins. 5. Install heat shield onto mounting stud. 6. Install heat shield retaining nut and tighten. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 2779 7. Connect the electrical connector. 8. Connect negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor Coolant Temperature Sensor/Switch (For Computer): Technical Service Bulletins Engine Controls MIL On/DTC P0116/ECT Sensor NUMBER: 18-039-06 GROUP: Vehicle Performance DATE: December 6, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES FOR StarSCAN. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 7.02 SP2 OR HIGHER FOR THIS BULLETIN. SUBJECT: Flash: MIL Illumination DTC P0116 - Engine Coolant Temperature Sensor Performance OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) and the Transmission Control Module (1CM) with new software. CAUTION: VEHICLES EQUIPPED WITH A CVT TRANSMISSION MUST HAVE THE TRANSMISSION CONTROL MODULE (TCM) CHECKED FOR THE LATEST SOFTWARE LEVEL WHENEVER THE PCM SOFTWARE IS UPGRADED. IF NEWER TCM SOFTWARE IS AVAILABLE, IT MUST BE INSTALLED. MODELS: 2007 (PM) Caliber 2007 (MK49) Compass NOTE: This bulletin applies to PM/MK models equipped with a 1.8L, 2.0L or 2.4L gasoline engine (Sales Code EBA, ECN or ED3) and block heater (Sales Code NHK) built before November 20, 2006 (MDH 1120XX). NOTE: If an aftermarket or MOPAR accessory block heater is installed, the same conditions may apply. SYMPTOM/CONDITION: Some customers may experience MIL illumination after using the block heater. No other symptoms will be experienced. The technician may find the following DTC's: ^ P0116 - ENGINE COOLANT TEMPERATURE SENSOR PERFORMANCE DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If MIL illumination with DTC P0116 is present, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 2784 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING **STEP 5n and/or 8h**. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 7.02 SP2 software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. PM/MK Models equipped with a CVT must have the TCM reprogrammed as follows: 6. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. 7. Is the TCM part number recorded in step 6e above, the same as the new p/n shown on the "Flash File List" screen? a. Yes >> No further action is necessary. Proceed to Step 9. b. No >> the TCM will require flash reprogramming, proceed to Step 8. 8. Flash reprogram the TCM as follows: a. From the "Flash File List" screen, select "Download to Scantool". b. Select "Close" after the download is complete, then select "Back". c. Highlight the listed calibration. d. Select "Update Controller". Follow on screen instructions. e. When the update is complete, select "OK". f. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. g. Turn the ignition switch to the OFF position for no less than 15 seconds. h. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 2785 CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the TCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. ** NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 9. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Sensor-Engine Coolant Temperature 1 Coolant Temperature Sensor/Switch (For Computer): Locations Sensor-Engine Coolant Temperature 1 Component ID: 290 Component : SENSOR-ENGINE COOLANT TEMPERATURE 1 Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE 1 Color : DK. GRAY # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 SENSOR GROUND K900 20DB/DG 2 ECT 1 SIGNAL K2 20VT/OR Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Sensor-Engine Coolant Temperature 1 > Page 2788 Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Sensor-Engine Coolant Temperature 1 > Page 2789 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Sensor-Engine Coolant Temperature 1 > Page 2790 Coolant Temperature Sensor/Switch (For Computer): Locations Sensor-Engine Coolant Temperature 2 Component ID: 291 Component : SENSOR-ENGINE COOLANT TEMPERATURE 2 Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE 2 Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 SENSOR GROUND K915 20BR/WT 2 ECT 2 SIGNAL K222 20BR/YL Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Sensor-Engine Coolant Temperature 1 > Page 2791 Component Location - 15 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Sensor-Engine Coolant Temperature 1 > Page 2792 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Sensor-Engine Coolant Temperature 1 Coolant Temperature Sensor/Switch (For Computer): Diagrams Sensor-Engine Coolant Temperature 1 Component ID: 290 Component : SENSOR-ENGINE COOLANT TEMPERATURE 1 Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE 1 Color : DK. GRAY # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 SENSOR GROUND K900 20DB/DG 2 ECT 1 SIGNAL K2 20VT/OR Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Sensor-Engine Coolant Temperature 1 > Page 2795 Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Sensor-Engine Coolant Temperature 1 > Page 2796 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Sensor-Engine Coolant Temperature 1 > Page 2797 Coolant Temperature Sensor/Switch (For Computer): Diagrams Sensor-Engine Coolant Temperature 2 Component ID: 291 Component : SENSOR-ENGINE COOLANT TEMPERATURE 2 Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE 2 Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 SENSOR GROUND K915 20BR/WT 2 ECT 2 SIGNAL K222 20BR/YL Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Sensor-Engine Coolant Temperature 1 > Page 2798 Component Location - 15 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Sensor-Engine Coolant Temperature 1 > Page 2799 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Component ID: 287 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 CKP SENSOR 5 VOLT SUPPLY K853 20DB/BR 2 CKP SENSOR SIGNAL K24 20BR/LB 3 CKP SENSOR GROUND K925 20DB/WT Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2803 Component Location - 19 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2804 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2805 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20LB/BR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2806 Component Location - 16 Component Location - 19 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2807 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2808 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2809 Crankshaft Position Sensor: Diagrams Component ID: 287 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 CKP SENSOR 5 VOLT SUPPLY K853 20DB/BR 2 CKP SENSOR SIGNAL K24 20BR/LB 3 CKP SENSOR GROUND K925 20DB/WT Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2810 Component Location - 19 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2811 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2812 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20LB/BR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2813 Component Location - 16 Component Location - 19 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2814 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2815 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description DESCRIPTION The crankshaft position sensor mounts to the rear of the engine block near the transmission. The PCM uses the Crankshaft Position sensor to calculate the following: - Engine RPM - TDC number 1 and 4 - Ignition coil synchronization - Injector synchronization - Camshaft-to-crankshaft misalignment (Timing belt skipped 1 tooth or more diagnostic trouble code). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 2818 Crankshaft Position Sensor: Description and Operation Operation OPERATION The PCM sends approximately 5 volts to the Hall-effect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. A ground for the sensor is provided through the sensor return circuit. The input to the PCM occurs on a 5 volt output reference circuit that operates as follows: The Hall-effect sensor contains a powerful magnet. As the magnetic field passes over the dense portion of the counterweight, the 5-volt signal is pulled to ground (0.3 volts) through a transistor in the sensor. When the magnetic field passes over the notches in the crankshaft counterweight, the magnetic field turns off the transistor in the sensor, causing the PCM to register the 5-volt signal. The PCM identifies crankshaft position by registering the change from 5 to 0 volts, as signaled from the Crankshaft Position sensor (2). The PCM determines which cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. The #8 crankshaft counterweight has a target ring with 32 teeth and notches (1), including one long reference tooth and notch. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Removal Crankshaft Position Sensor: Service and Repair Removal 2.0/2.4L The Crankshaft Position Sensor is in the rear of the engine block near the transmission. If vehicle is All Wheel Drive the Power Transfer Unit must be removed. 1. Disconnect the negative battery cable. 2. Raise vehicle and support. 3. Remove heat shield retaining bolt. 4. Remove heat shield. 5. Unlock and disconnect the electrical connector to the crankshaft position sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Removal > Page 2821 6. Remove the crankshaft position sensor bolt. 7. Remove the sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Removal > Page 2822 Crankshaft Position Sensor: Service and Repair Installation 2.0/2.4L 1. Check O-ring for damage and lubricate the O-ring with engine oil before installing sensor. 2. Use a twisting motion when installing the sensor. 3. Install and tighten the crankshaft position sensor bolt and tighten to 9 Nm (79.5 in. lbs.). 4. Connect and lock the electrical connector to the crankshaft position sensor. 5. Install heat shield and retaining bolt. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Removal > Page 2823 If vehicle is All Wheel Drive the Power Transfer Unit must be installed. 6. Lower vehicle. 7. Connect the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations Component ID: 297 Component : SENSOR-INTAKE AIR TEMPERATURE Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 IAT SIGNAL K21 20BK/RD 2 SENSOR GROUND K915 20BR/WT Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2827 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2828 Intake Air Temperature Sensor: Diagrams Component ID: 297 Component : SENSOR-INTAKE AIR TEMPERATURE Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 IAT SIGNAL K21 20BK/RD 2 SENSOR GROUND K915 20BR/WT Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2829 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2830 Intake Air Temperature Sensor: Description and Operation DESCRIPTION The IAT Sensor is a Negative Temperature Coefficient (NTC) Sensor that provides information to the PCM regarding the temperature of the air entering the intake manifold. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Removal Intake Air Temperature Sensor: Service and Repair Removal 2.0/2.4L The sensor is located in the clean air duct. 1. Disconnect the negative battery cable. 2. Disconnect electrical connector from the sensor. 3. Remove the sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Removal > Page 2833 Intake Air Temperature Sensor: Service and Repair Installation 2.0/2.4L The sensor is in the clean air duct. 1. Install sensor. Make sure of sensor orientation. 2. Attach electrical connector to sensor. 3. Connect the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Component ID: 299 Component : SENSOR-KNOCK Connector: Name : SENSOR-KNOCK Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 KS SIGNAL K42 20LG/DB 2 KS RETURN K942 20WT/BR Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2837 Component Location - 15 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2838 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2839 Knock Sensor: Diagrams Component ID: 299 Component : SENSOR-KNOCK Connector: Name : SENSOR-KNOCK Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 KS SIGNAL K42 20LG/DB 2 KS RETURN K942 20WT/BR Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2840 Component Location - 15 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2841 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Description Knock Sensor: Description and Operation Description DESCRIPTION The knock sensor is bolted to the cylinder block. The knock sensor is designed to detect engine vibration that is caused by detonation or preignition. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Description > Page 2844 Knock Sensor: Description and Operation Operation OPERATION When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives as an input the knock sensor voltage signal. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, ignition timing retard is allowed. Ignition timing is retarded uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard ignition timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except WOT. The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening affects knock sensor performance, possibly causing improper spark control. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Removal Knock Sensor: Service and Repair Removal 2.0/2.4L The knock sensor bolts into the side of the cylinder block in front of the starter under the intake manifold. 1. Disconnect the negative battery cable. 2. Remove the bolt holding the knock sensor. 3. Remove sensor with electrical connector attached. 4. Disconnect electrical connector from knock sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Removal > Page 2847 5. Remove the knock sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Removal > Page 2848 Knock Sensor: Service and Repair Installation 2.0/2.4L The knock sensor bolts into the side of the cylinder block in front of the starter under the intake manifold. 1. Attach electrical connector to knock sensor. 2. Install knock sensor. Tighten knock sensor bolt to 22 Nm (195 in. lbs.). Over or under tightening effects knock sensor performance, possibly causing improper spark control. 3. Connect the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations Component ID: 300 Component : SENSOR-MAP Connector: Name : SENSOR-MAP Color : BLACK # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 MAP SIGNAL K1 20VT/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY K857 20BR/LG Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2852 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2853 Manifold Pressure/Vacuum Sensor: Diagrams Component ID: 300 Component : SENSOR-MAP Connector: Name : SENSOR-MAP Color : BLACK # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 MAP SIGNAL K1 20VT/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY K857 20BR/LG Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2854 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Description Manifold Pressure/Vacuum Sensor: Description and Operation Description DESCRIPTION The MAP sensor mounts to the intake manifold. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Description > Page 2857 Manifold Pressure/Vacuum Sensor: Description and Operation Operation OPERATION The MAP serves as a PCM input, using a silicon based sensing unit, to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When MAP equals Barometric pressure, the pulse width will be at maximum. Also like the cam and crank sensors, a 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5 volt and full scale is 4.5 volt. For a pressure swing of 0 - 15 psi the voltage changes 4.0 volt. The sensor is supplied a regulated 4.8 to 5.1 volts to operate the sensor. Like the cam and crank sensors ground is provided through the sensor return circuit. The MAP sensor input is the number one contributor to pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or is it in Denver at 5000 feet above sea level, because the air density changes with altitude. It will also help to correct for varying weather conditions. If a hurricane was coming through the pressure would be very, very low or there could be a real fair weather, high pressure area. This is important because as air pressure changes the barometric pressure changes. Barometric pressure and altitude have a direct inverse correlation, as altitude goes up barometric goes down. The first thing that happens as the key is rolled on, before reaching the crank position, the PCM powers up, comes around and looks at the MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure relative to altitude. Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key on. The difference between current and what it was at key on is manifold vacuum. During key On (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring known good sensor in your work area. As the altitude increases the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key On the barometric pressure needs to be updated. Any time the PCM sees Wide Open throttle, based upon TPS angle and RPM it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively. The PCM uses the MAP sensor to aid in calculating the following: - Barometric pressure - Engine load - Manifold pressure - Injector pulse-width - Spark-advance programs - Shift-point strategies (F4AC1 transmissions only, via the PCI bus) - Idle speed - Decel fuel shutoff The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 88 kPa (26 in. Hg). Barometric pressure is the pressure exerted by the atmosphere upon an object. At sea level on a standard day, no storm, barometric pressure is 101 kPa (29.92 in. Hg). For every 30.5 meters (100 feet) of altitude barometric pressure drops .33 kPa (0.10 in. Hg). If a storm goes through it can either add, high pressure, or decrease, low pressure, from what should be present for that altitude. You should make a habit of knowing what the average pressure and corresponding barometric pressure is for your area. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal Manifold Pressure/Vacuum Sensor: Service and Repair Removal 2.0/2.4L 1. Remove the air cleaner cover. 2. Disconnect the negative battery cable. 3. Disconnect the electrical connector from the MAP sensor. 4. Remove the screws from the MAP sensor. 5. Remove the MAP sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 2860 Manifold Pressure/Vacuum Sensor: Service and Repair Installation 2.0/2.4L 1. Make sure that the manifold is clean. 2. Install sensor to manifold. 3. Tighten screw. 4. Connect the electrical connector to the sensor. 5. Connect the negative battery cable. 6. Install the air cleaner cover. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 Oxygen Sensor: Locations Sensor - Oxygen 1/1 Component ID: 304 Component : SENSOR-OXYGEN 1/1 Connector: Name : SENSOR-OXYGEN 1/1 Color : GRAY # of pins : 4 Qualifier : (GAS) Pin Description Circuit 1 GROUND Z916 18BK 2 O2 1/1 HEATER CONTROL K99 20BR/OR 3 O2 1/1 RETURN K902 20BR/DG 4 O2 1/1 SIGNAL K41 20BK/DG Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 2865 Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 2866 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 2867 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 2868 Oxygen Sensor: Locations Sensor - Oxygen 1/2 Component ID: 305 Component : SENSOR-OXYGEN 1/2 Connector: Name : SENSOR-OXYGEN 1/2 Color : BLACK # of pins : 4 Qualifier : (GAS) Pin Description Circuit 1 GROUND Z924 18BK/LB 2 O2 1/2 HEATER CONTROL K299 20BR/RD 3 O2 1/2 RETURN K904 20DB/DG 4 O2 1/2 SIGNAL K141 20DB/YL Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 2869 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 2870 Oxygen Sensor: Locations 1/1 Upstream - 2.0/2.4L The upstream oxygen sensor threads into the outlet flange of the exhaust manifold. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 2871 Oxygen Sensor: Locations 1/2 Downstream - 2.0/2.4L The downstream heated oxygen sensor threads into the catalytic converter. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Sensor-Oxygen 1/1 Oxygen Sensor: Diagrams Sensor-Oxygen 1/1 Component ID: 304 Component : SENSOR-OXYGEN 1/1 Connector: Name : SENSOR-OXYGEN 1/1 Color : GRAY # of pins : 4 Qualifier : (GAS) Pin Description Circuit 1 GROUND Z916 18BK 2 O2 1/1 HEATER CONTROL K99 20BR/OR 3 O2 1/1 RETURN K902 20BR/DG 4 O2 1/1 SIGNAL K41 20BK/DG Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Sensor-Oxygen 1/1 > Page 2874 Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Sensor-Oxygen 1/1 > Page 2875 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Sensor-Oxygen 1/1 > Page 2876 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Sensor-Oxygen 1/1 > Page 2877 Oxygen Sensor: Diagrams Sensor-Oxygen 1/2 Component ID: 305 Component : SENSOR-OXYGEN 1/2 Connector: Name : SENSOR-OXYGEN 1/2 Color : BLACK # of pins : 4 Qualifier : (GAS) Pin Description Circuit 1 GROUND Z924 18BK/LB 2 O2 1/2 HEATER CONTROL K299 20BR/RD 3 O2 1/2 RETURN K904 20DB/DG 4 O2 1/2 SIGNAL K141 20DB/YL Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Sensor-Oxygen 1/1 > Page 2878 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2879 Oxygen Sensor: Application and ID - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description Oxygen Sensor: Description and Operation Description DESCRIPTION The upstream oxygen sensor threads into the outlet flange of the exhaust manifold. The downstream heated oxygen sensor threads into the system depending on emission package. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description > Page 2882 Oxygen Sensor: Description and Operation Operation OPERATION Separate upstream and downstream grounds are used on the NGC vehicles (4 Cyl.). As vehicles accumulate mileage, the catalytic convertor deteriorates. The deterioration results in a less efficient catalyst. To monitor catalytic convertor deterioration, the fuel injection system uses two heated oxygen sensors. One sensor upstream of the catalytic convertor, one downstream of the convertor. The PCM compares the reading from the sensors to calculate the catalytic convertor oxygen storage capacity and converter efficiency. Also, the PCM uses the upstream heated oxygen sensor input when adjusting injector pulse width. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the malfunction indicator lamp (MIL). The O2 sensors produce a constant 2.5 volts on NGC vehicles, depending upon the oxygen content of the exhaust gas. When a large amount of oxygen is present (caused by a lean air/fuel mixture, can be caused by misfire and exhaust leaks), the sensors produce a low voltage. When there is a lesser amount of oxygen present (caused by a rich air/fuel mixture, which can be caused by internal engine problems) it produces a higher voltage. By monitoring the oxygen content and converting it to electrical voltage, the sensors act as a rich-lean switch. The oxygen sensors are equipped with a heating element that keeps the sensors at proper operating temperature during all operating modes. Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop operation the PCM monitors the O2 sensor's input (along with other inputs) and adjusts the injector pulse width accordingly. During Open Loop operation the PCM ignores the O2 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. The NGC Controller has a common ground for the heater in the O2S. 12 volts is supplied to the heater in the O2S by the NGC controller. Both the upstream and downstream O2 sensors for NGC are pulse width modulation (PWM). NOTE: When replacing an O2 Sensor, the PCM RAM memory must be cleared, either by disconnecting the PCM C-1 connector or momentarily disconnecting the Battery negative terminal. The NGC learns the characteristics of each O2 heater element and these old values should be cleared when installing a new O2 sensor. The customer may experience driveability issues if this is not performed. UPSTREAM OXYGEN SENSOR The input from the upstream heated oxygen sensor tells the PCM the oxygen content of the exhaust gas. Based on this input, the PCM fine tunes the air-fuel ratio by adjusting injector pulse width. The sensor input switches from 2.5 to 3.5 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air-fuel mixture), the sensor produces voltage as low as 2.5 volt. When there is a lesser amount of oxygen present (rich air-fuel mixture) the sensor produces a voltage as high as 3.5 volt. By monitoring the oxygen content and converting it to electrical voltage, the sensor acts as a rich-lean switch. The heating element in the sensor provides heat to the sensor ceramic element. Heating the sensor allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop, the PCM adjusts injector pulse width based on the upstream heated oxygen sensor input along with other inputs. In Open Loop, the PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. DOWNSTREAM OXYGEN SENSOR The downstream heated oxygen sensor input is used to detect catalytic convertor deterioration. As the convertor deteriorates, the input from the downstream sensor begins to match the upstream sensor input except for a slight time delay. By comparing the downstream heated oxygen sensor input to the input from the upstream sensor, the PCM calculates catalytic convertor efficiency. This is also used to establish the upstream O2 goal voltage (switching point). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal Oxygen Sensor: Service and Repair Removal 1/1 Upstream - 2.0/2.4L 1/1 UPSTREAM - 2.0/2.4L 1. Remove the engine cover. 2. Remove the negative battery cable. 3. Disconnect electrical connector from O2 sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 2885 4. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent. 1/2 Downstream - 2.0/2.4L 1/2 DOWNSTREAM - 2.0/2.4L Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 2886 The downstream heated oxygen sensor threads into the catalytic converter. 1. Remove the negative battery cable. 2. Raise vehicle and support. 3. Disconnect electrical connector from sensor. 4. Disconnect sensor electrical harness from clips along body. 5. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 2887 Oxygen Sensor: Service and Repair Installation 1/1 Upstream - 2.0/2.4L 1/1 UPSTREAM - 2.0/2.4L 1. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite(R) 771-64 or equivalent. New sensors have compound on the threads and do not require an additional coating. Tighten the sensor to 41 Nm (30 ft. lbs.). 2. Install sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 2888 3. Connect electrical connector to sensor. 4. Install the negative battery cable. 5. Install the engine cover. 1/2 Downstream - 2.0/2.4L 1/2 DOWNSTREAM - 2.0/2.4L Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 2889 The downstream heated oxygen sensor threads into the exhaust pipe behind the catalytic converter. 1. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite(R) 771-64 or equivalent. New sensors have compound on the threads and do not require an additional coating. Tighten the sensor to 41 Nm (30 ft. lbs.). 2. Install sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent. 3. Connect sensor electrical harness to clips along body. 4. Connect electrical connector to sensor. 5. Lower vehicle. 6. Install the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Page 2890 Oxygen Sensor: Tools and Equipment FUEL O2S (Oxygen Sensor) Remover/Installer-C-4907 O2S (Oxygen Sensor) Remover/Installer - 8439 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations Component ID: 318 Component : SENSOR-VEHICLE SPEED Connector: Name : SENSOR-VEHICLE SPEED Color : BLACK # of pins : 3 Qualifier : (GAS MTX) Pin Description Circuit 1 5 VOLT SUPPLY F856 20YL/PK 2 SENSOR GROUND K914 18BR/WT 3 VEHICLE SPEED SIGNAL K75 18WT/OR Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 2894 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: Provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2897 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2898 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2899 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2900 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2901 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2902 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2903 5. Release the Secondary Terminal Lock, if required (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2904 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2905 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2906 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2907 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2908 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2909 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2910 Vehicle Speed Sensor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2911 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2912 STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2913 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2914 Vehicle Speed Sensor: Connector Views Component ID: 318 Component : SENSOR-VEHICLE SPEED Connector: Name : SENSOR-VEHICLE SPEED Color : BLACK # of pins : 3 Qualifier : (GAS MTX) Pin Description Circuit 1 5 VOLT SUPPLY F856 20YL/PK 2 SENSOR GROUND K914 18BR/WT 3 VEHICLE SPEED SIGNAL K75 18WT/OR Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2915 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Component ID: 281 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 APP SIGNAL 2 K29 20WT/BR 2 APP SENSOR GROUND 2 K400 20BR/VT 3 5 VOLT SUPPLY K854 20VT/BR 3 5 VOLT SUPPLY K858 20BR/GY 4 APP SIGNAL 1 K23 20BR/OR 5 APP SENSOR GROUND 1 K167 20BR/YL 6 5 VOLT SUPPLY K852 20BR/VT 6 5 VOLT SUPPLY F856 20YL/PK Component Location - 44 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2920 Component Location - 47 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2921 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2922 Accelerator Pedal Position Sensor: Diagrams Component ID: 281 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 APP SIGNAL 2 K29 20WT/BR 2 APP SENSOR GROUND 2 K400 20BR/VT 3 5 VOLT SUPPLY K854 20VT/BR 3 5 VOLT SUPPLY K858 20BR/GY 4 APP SIGNAL 1 K23 20BR/OR 5 APP SENSOR GROUND 1 K167 20BR/YL 6 5 VOLT SUPPLY K852 20BR/VT 6 5 VOLT SUPPLY F856 20YL/PK Component Location - 44 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2923 Component Location - 47 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2924 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2925 Accelerator Pedal Position Sensor: Description and Operation DESCRIPTION The Accelerator Pedal Position Sensor (APPS) is a variable resistor that provides the PCM with an input signal (voltage). The signal represents pedal angle position. As the position of the accelerator pedal changes, the resistance of the APPS changes. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal Accelerator Pedal Position Sensor: Service and Repair Removal REMOVAL 1. Disconnect negative battery cable. 2. Disconnect the electrical connector from the module. 3. Remove the mounting nuts. 4. Remove assembly from the mounting studs. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal > Page 2928 Accelerator Pedal Position Sensor: Service and Repair Installation INSTALLATION 1. Install APPS module. 2. Tighten the mounting nuts. 3. Connect electrical connector. 4. Connect negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Description and Operation Turbo Boost Sensor: Description and Operation DESCRIPTION Turbocharged vehicles are equipped with three solenoids that are PCM controlled. They are mounted to the right shock tower. A vacuum harness connects the solenoids to their respective component. - Wastegate Actuator Solenoid - Surge Valve Actuator Solenoid - Throttle Inlet Pressure (TIP) Solenoid Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Service and Repair > Removal Turbo Boost Sensor: Service and Repair Removal REMOVAL 1. Remove nuts (1) securing solenoid mounting bracket to shock tower. 2. Disconnect solenoid electrical connector. 3. Disconnect vacuum harness connector from solenoid. 4. Push on solenoid lock tab (1) and slide solenoid off bracket. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Service and Repair > Removal > Page 2934 Turbo Boost Sensor: Service and Repair Installation INSTALLATION 1. Slide solenoid onto mounting bracket until lock tab engages. 2. Connect vacuum harness connector to solenoid. 3. Connect solenoid electrical connector. 4. Install nuts securing solenoid mounting bracket to shock tower. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Sensor-Camshaft 1/1 Position Camshaft Position Sensor: Locations Sensor-Camshaft 1/1 Position Component ID: 284 Component : SENSOR-CAMSHAFT 1/1 POSITION Connector: Name : SENSOR-CAMSHAFT 1/1 POSITION Color : BLACK # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY K857 20BR/LG 2 SENSOR GROUND K900 20DB/DG 3 CMP 1/1 SIGNAL K44 20DB Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Sensor-Camshaft 1/1 Position > Page 2940 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Sensor-Camshaft 1/1 Position > Page 2941 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Sensor-Camshaft 1/1 Position > Page 2942 Camshaft Position Sensor: Locations Sensor-Camshaft 1/2 Position Component ID: 285 Component : SENSOR-CAMSHAFT 1/2 POSITION Connector: Name : SENSOR-CAMSHAFT 1/2 POSITION Color : BLACK # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K915 20BR/WT 3 CMP 1/2 SIGNAL K441 20DB/BR Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Sensor-Camshaft 1/1 Position > Page 2943 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Sensor-Camshaft 1/1 Position Camshaft Position Sensor: Diagrams Sensor-Camshaft 1/1 Position Component ID: 284 Component : SENSOR-CAMSHAFT 1/1 POSITION Connector: Name : SENSOR-CAMSHAFT 1/1 POSITION Color : BLACK # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY K857 20BR/LG 2 SENSOR GROUND K900 20DB/DG 3 CMP 1/1 SIGNAL K44 20DB Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Sensor-Camshaft 1/1 Position > Page 2946 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Sensor-Camshaft 1/1 Position > Page 2947 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Sensor-Camshaft 1/1 Position > Page 2948 Camshaft Position Sensor: Diagrams Sensor-Camshaft 1/2 Position Component ID: 285 Component : SENSOR-CAMSHAFT 1/2 POSITION Connector: Name : SENSOR-CAMSHAFT 1/2 POSITION Color : BLACK # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K915 20BR/WT 3 CMP 1/2 SIGNAL K441 20DB/BR Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Sensor-Camshaft 1/1 Position > Page 2949 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Description Camshaft Position Sensor: Description and Operation Description DESCRIPTION The camshaft position sensors are mounted to the front and rear of the cylinder head. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Description > Page 2952 Camshaft Position Sensor: Description and Operation Operation OPERATION The PCM sends approximately 5 volts to the Hall-effect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. The input to the PCM occurs on a 5 volt output reference circuit. A ground for the sensor is provided through the sensor return circuit. The PCM identifies camshaft position by registering the change from 5 to 0 volts, as signaled from the camshaft position sensor. The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Removal Camshaft Position Sensor: Service and Repair Removal Front Camshaft Position Sensor FRONT CAMSHAFT POSITION SENSOR 1. Remove the air cleaner hose to throttle body, disconnect the inlet air temperature sensor electrical connector. 2. Disconnect negative battery cable. 3. Disconnect electrical connector from camshaft position sensor. 4. Remove camshaft position sensor mounting screws. 5. Remove sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 2955 Rear Camshaft Position Sensor REAR CAMSHAFT POSITION SENSOR 1. Disconnect negative battery cable. 2. Disconnect electrical connector at sensor. 3. Remove nut retaining heat shield. 4. Pull heat shield out to uncover sensor. 5. Remove mounting bolt. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 2956 6. Remove sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 2957 Camshaft Position Sensor: Service and Repair Installation Front Camshaft Position Sensor FRONT CAMSHAFT POSITION SENSOR 1. Lubricate sensor O-ring. 2. Install camshaft position sensor utilizing twisting motion. Make sure sensor is fully seated. Do not drive sensor into the bore with screw. This can cause sensor to be incorrectly seated causing engine to fail. Tighten sensor mounting screws to 9 Nm (79.5 in. lbs.). 3. Carefully attach electrical connector to camshaft position sensor. Installation at an angle may damage the sensor pins. 4. Install the negative battery cable. 5. Install the air cleaner to throttle body hose, connect the inlet air temperature sensor electrical connector. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 2958 Rear Camshaft Position Sensor REAR CAMSHAFT POSITION SENSOR 1. Lubricate sensor O-ring. 2. Install sensor utilizing twisting motion. Make sure sensor is fully seated. Do not drive sensor into the bore with screw. This can cause sensor to be incorrectly seated causing engine to fail. 3. Install mounting bolt and tighten to 9 Nm (79.5 in. lbs.). 4. Carefully attach electrical connector to camshaft position sensor. Fill for positive lock (click). Installation at angle may damage the sensor pins. 5. Install heat shield onto mounting stud. 6. Install heat shield retaining nut and tighten. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 2959 7. Connect the electrical connector. 8. Connect negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Component ID: 287 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 CKP SENSOR 5 VOLT SUPPLY K853 20DB/BR 2 CKP SENSOR SIGNAL K24 20BR/LB 3 CKP SENSOR GROUND K925 20DB/WT Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2963 Component Location - 19 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2964 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2965 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20LB/BR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2966 Component Location - 16 Component Location - 19 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2967 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2968 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2969 Crankshaft Position Sensor: Diagrams Component ID: 287 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 CKP SENSOR 5 VOLT SUPPLY K853 20DB/BR 2 CKP SENSOR SIGNAL K24 20BR/LB 3 CKP SENSOR GROUND K925 20DB/WT Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2970 Component Location - 19 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2971 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2972 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20LB/BR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2973 Component Location - 16 Component Location - 19 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2974 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2975 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description DESCRIPTION The crankshaft position sensor mounts to the rear of the engine block near the transmission. The PCM uses the Crankshaft Position sensor to calculate the following: - Engine RPM - TDC number 1 and 4 - Ignition coil synchronization - Injector synchronization - Camshaft-to-crankshaft misalignment (Timing belt skipped 1 tooth or more diagnostic trouble code). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 2978 Crankshaft Position Sensor: Description and Operation Operation OPERATION The PCM sends approximately 5 volts to the Hall-effect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. A ground for the sensor is provided through the sensor return circuit. The input to the PCM occurs on a 5 volt output reference circuit that operates as follows: The Hall-effect sensor contains a powerful magnet. As the magnetic field passes over the dense portion of the counterweight, the 5-volt signal is pulled to ground (0.3 volts) through a transistor in the sensor. When the magnetic field passes over the notches in the crankshaft counterweight, the magnetic field turns off the transistor in the sensor, causing the PCM to register the 5-volt signal. The PCM identifies crankshaft position by registering the change from 5 to 0 volts, as signaled from the Crankshaft Position sensor (2). The PCM determines which cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. The #8 crankshaft counterweight has a target ring with 32 teeth and notches (1), including one long reference tooth and notch. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Removal Crankshaft Position Sensor: Service and Repair Removal 2.0/2.4L The Crankshaft Position Sensor is in the rear of the engine block near the transmission. If vehicle is All Wheel Drive the Power Transfer Unit must be removed. 1. Disconnect the negative battery cable. 2. Raise vehicle and support. 3. Remove heat shield retaining bolt. 4. Remove heat shield. 5. Unlock and disconnect the electrical connector to the crankshaft position sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Removal > Page 2981 6. Remove the crankshaft position sensor bolt. 7. Remove the sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Removal > Page 2982 Crankshaft Position Sensor: Service and Repair Installation 2.0/2.4L 1. Check O-ring for damage and lubricate the O-ring with engine oil before installing sensor. 2. Use a twisting motion when installing the sensor. 3. Install and tighten the crankshaft position sensor bolt and tighten to 9 Nm (79.5 in. lbs.). 4. Connect and lock the electrical connector to the crankshaft position sensor. 5. Install heat shield and retaining bolt. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Removal > Page 2983 If vehicle is All Wheel Drive the Power Transfer Unit must be installed. 6. Lower vehicle. 7. Connect the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder Ignition Switch Lock Cylinder: Service and Repair Key/Lock Cylinder Removal REMOVAL 1. Access and remove the Steering Column Control Module (SCCM) (3) from the steering column (2). 2. If equipped with Thatcham security (Export), remove the screws securing the cup (1) over the key cylinder. Remove the cup. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 2989 3. Remove the screw (1) fastening the SKREEM/WCM (2) to the lock cylinder housing (3). 4. Unhook the SKREEM/WCM (2) retainer fingers from the lock cylinder housing (3) and remove it. 5. Insert the key (2) and turn the key cylinder (3) to the RUN position. 6. Insert an appropriate tool into the slot (1) formed into the lock cylinder housing depressing the key cylinder retaining tab. 7. Pull the key cylinder and key straight out of the lock cylinder housing as one unit. 8. Using a Tamper-Proof Torx(R) Plus (five point) 30 bit, remove the two screws (1) fastening the lock cylinder housing (2) to the column. 9. Remove the lock cylinder housing from the steering column. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 2990 10. Remove the ignition module (2) mounting screw (1). 11. Pull the module (1) straight out and off the retaining tabs (2) located on the lock cylinder housing. Installation INSTALLATION NOTE: Ignition module must be installed prior to lock housing installation on column. Otherwise, the tilt lever will obstruct installation of ignition switch. 1. Ensure the ignition module is in the RUN position and the actuator shaft in the lock housing is in the RUN position. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 2991 2. Align the ignition module with the pin (3), actuator shaft and retaining tabs (2) located on the lock cylinder housing. Carefully install the module, snapping it into place over the retaining tabs. 3. Install the ignition module (2) mounting screw (1). Tighten the screw to 2 Nm (18 in. lbs.). NOTE: Ignition module needs to be installed on lock cylinder housing before housing installation to clear tilt lever. 4. Position the lock cylinder housing in the RUN position. 5. Align the lock cylinder housing (2) with the steering column. 6. Install the two screws (1) fastening the lock cylinder housing (2) to the column. Tighten the screws to 12 Nm (110 in. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 2992 7. Place the actuator in the lock cylinder housing to the RUN position (if not already there). 8. Insert the key into the key cylinder and turn the key cylinder to the RUN position. 9. Align the retaining tab on the key cylinder with the slot in the top of the lock cylinder housing. 10. Slide the key cylinder into the lock cylinder housing until the key cylinder retaining tab locks the cylinder into place. 11. Rotate the key back and forth (OFF to START), then remove and reinstall it, making sure the key cylinder and lock cylinder housing operate properly. 12. Slide the ring of the SKREEM/WCM (2) over the lock cylinder housing (3) and engage the retainer fingers in the recesses formed on the lock cylinder housing. 13. Install the screw (1) fastening the SKREEM/WCM (2) to the lock cylinder housing (3). Tighten the screw to 2.5 Nm (22 in. lbs.). 14. If equipped with Thatcham security (Export), install the cup (1) over the key cylinder and install the two mounting screws. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 2993 15. Install the Steering Column Control Module (SCCM) (3) and all components removed to access it. 16. Check operation of all steering column mounted components. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 2994 Ignition Switch Lock Cylinder: Service and Repair Housing-Lock Cylinder Removal REMOVAL 1. Access and remove the Steering Column Control Module (SCCM) (3) from the steering column (2). 2. If equipped with Thatcham security, remove the screws securing the cup (1) over the key cylinder. Remove the cup. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 2995 3. Remove the screw (1) fastening the SKREEM/WCM (2) to the lock cylinder housing (3). 4. Unhook the SKREEM/WCM (2) retainer fingers from the lock cylinder housing (3) and remove it. 5. Insert the key (2) and turn the key cylinder (3) to the RUN position. 6. Insert an appropriate tool into the slot (1) formed into the lock cylinder housing depressing the key cylinder retaining tab. 7. Pull the key cylinder and key straight out of the lock cylinder housing as one unit. 8. Using a Tamper-Proof Torx(R) Plus (five point) 30 bit, remove the two screws (1) fastening the lock cylinder housing (2) to the column. 9. Remove the lock cylinder housing from the steering column. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 2996 10. Remove the ignition module (2) mounting screw (1). 11. Pull the module (1) straight out and off the retaining tabs (2) located on the lock cylinder housing. Installation INSTALLATION NOTE: Ignition module must be installed prior to lock housing installation on column. Otherwise, the tilt lever will obstruct installation of ignition switch. 1. Ensure the ignition module is in the RUN position and the actuator shaft in the lock housing is in the RUN position. 2. Align the ignition module with the pin (3), actuator shaft and retaining tabs (2) located on the lock cylinder housing. Carefully install the module, snapping it into place over the retaining tabs. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 2997 3. Install the ignition module (2) mounting screw (1). Tighten the screw to 2 Nm (18 in. lbs.). NOTE: Ignition module needs to be installed on lock cylinder housing before housing installation to clear tilt lever. 4. Position the lock cylinder housing in the RUN position. 5. Align the lock cylinder housing (2) with the steering column. 6. Install the two screws (1) fastening the lock cylinder housing (2) to the column. Tighten the screws to 12 Nm (110 in. lbs.). 7. Place the actuator in the lock cylinder housing to the RUN position (if not already there). 8. Insert the key into the key cylinder and turn the key cylinder to the RUN position. 9. Align the retaining tab on the key cylinder with the slot in the top of the lock cylinder housing. 10. Slide the key cylinder into the lock cylinder housing until the key cylinder retaining tab locks the cylinder into place. 11. Rotate the key back and forth (OFF to START), then remove and reinstall it, making sure the key cylinder and lock cylinder housing operate Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 2998 properly. 12. Slide the ring of the SKREEM/WCM (2) over the lock cylinder housing (3) and engage the retainer fingers in the recesses formed on the lock cylinder housing. 13. Install the screw (1) fastening the SKREEM/WCM (2) to the lock cylinder housing (3). Tighten the screw to 2.5 Nm (22 in. lbs.). 14. If equipped with Thatcham security, install the cup (1) over the key cylinder and install the two mounting screws. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 2999 15. Install the Steering Column Control Module (SCCM) (3) and all components removed to access it. 16. Check operation of all steering column mounted components. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Component ID: 299 Component : SENSOR-KNOCK Connector: Name : SENSOR-KNOCK Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 KS SIGNAL K42 20LG/DB 2 KS RETURN K942 20WT/BR Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3003 Component Location - 15 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3004 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3005 Knock Sensor: Diagrams Component ID: 299 Component : SENSOR-KNOCK Connector: Name : SENSOR-KNOCK Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 KS SIGNAL K42 20LG/DB 2 KS RETURN K942 20WT/BR Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3006 Component Location - 15 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3007 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Description Knock Sensor: Description and Operation Description DESCRIPTION The knock sensor is bolted to the cylinder block. The knock sensor is designed to detect engine vibration that is caused by detonation or preignition. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Description > Page 3010 Knock Sensor: Description and Operation Operation OPERATION When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives as an input the knock sensor voltage signal. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, ignition timing retard is allowed. Ignition timing is retarded uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard ignition timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except WOT. The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening affects knock sensor performance, possibly causing improper spark control. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Removal Knock Sensor: Service and Repair Removal 2.0/2.4L The knock sensor bolts into the side of the cylinder block in front of the starter under the intake manifold. 1. Disconnect the negative battery cable. 2. Remove the bolt holding the knock sensor. 3. Remove sensor with electrical connector attached. 4. Disconnect electrical connector from knock sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Removal > Page 3013 5. Remove the knock sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Removal > Page 3014 Knock Sensor: Service and Repair Installation 2.0/2.4L The knock sensor bolts into the side of the cylinder block in front of the starter under the intake manifold. 1. Attach electrical connector to knock sensor. 2. Install knock sensor. Tighten knock sensor bolt to 22 Nm (195 in. lbs.). Over or under tightening effects knock sensor performance, possibly causing improper spark control. 3. Connect the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL SYSTEM PRESSURE Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 3019 Fuel Pressure: Testing and Inspection *CHECKING THE FUEL DELIVERY SYSTEM For a complete wiring diagram refer to Diagrams/Electrical. Diagnostic Test 1. CHECKING THE FUEL PUMP OPERATION Turn the ignition on. NOTE: Diagnose and repair any fuel pump control circuit or relay DTCs before continuing with this test. With a scan tool, actuate the fuel pump control to ON (100%). NOTE: It may be necessary to use a mechanics stethoscope in the next step. Listen for fuel pump operation at the fuel tank. The fuel pump should operate smoothly, without excessive noise. If necessary, compare to a known good vehicle of similar year, make, and model. NOTE: If the pump has excessive noise or grinding, the pump should be replaced. caution: Stop all actuation tests before continuing. Is the fuel pump operating when actuated? Yes - Go to 2 No - Go to 7 2. CHECKING THE FUEL PRESSURE Turn the ignition off. WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in personal injury or death. Install a fuel pressure gauge on the fuel rail. Turn the ignition on. With the scan tool, actuate the fuel pump relay control. Observe the fuel pressure gauge. NOTE: The fuel pressure specification is 407 KPa ± 34 KPa (59 psi ± 5 psi). caution: Stop all actuation tests before continuing. Select the conclusion that best matches the result of the test: Fuel pressure is within the stated specification - Test complete. Fuel pressure is below the stated specification - Go to 3 Fuel pressure is above the stated specification - Replace the fuel filter/pressure regulator. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 3020 - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 3. RESTRICTED FUEL SUPPLY LINE Turn the ignition off. WARNING: The fuel system is under a constant pressure, even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in personal injury or death. Raise vehicle on hoist, and disconnect the fuel pressure line at the fuel pump module. Install special 5/16 fuel line adapter tool #6539 between disconnected fuel line and the fuel pump module. Attach a fuel pressure test gauge to the T fitting on tool #6539. Turn the ignition on. With the scan tool, actuate the fuel pump relay control. Observe the fuel pressure gauge. NOTE: Fuel pressure specification is 407 KPa ± 34 KPa (59 psi ± 5 psi). caution: Stop all actuation tests before proceeding. Is the fuel pressure within specification? Yes - Repair or replace fuel supply line as necessary. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 4 4. SADDLE FUEL TANK Is the vehicle equipped with a saddle type fuel tank? Yes - Go to 5 No - Go to 6 5. FUEL TANK SIPHON HOSE OR FUEL LINE RESTRICTED OR DAMAGED Turn the ignition off. WARNING: The fuel system is under a constant pressure, even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in personal injury or death. Gain access to the fuel pump module and the fuel tank module. Inspect the fuel line and siphon hose between the fuel pump module and the fuel tank module. Look for disconnected or damaged lines and hoses. Inspect the fuel pressure regulator for damage or a condition that might cause a fuel flow problem. Make sure that it is seated in the module properly. Were any problems found? Yes - Repair as necessary. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 3021 - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 6 6. FUEL PUMP INLET STRAINER Turn the ignition off. WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in personal injury or death. Remove the fuel pump module and inspect the fuel inlet strainer for damage or a condition that might cause a fuel flow problem. Were any problems found? Yes - Replace the Fuel Pump Inlet Strainer. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Replace the Fuel Pump Module. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 7. FUEL PUMP GROUND CIRCUIT OPEN OR HIGH RESISTANCE Turn the ignition off. Disconnect the Fuel Pump Module harness connector. Using a 12 volt test light connected to 12 volts, check the Fuel Pump Motor Ground circuit at the Fuel Pump Module harness connector. NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated and bright? Yes - Replace the Fuel Pump Module. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Repair the Fuel Pump Ground circuit for an open circuit or high resistance. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by manufacturer Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal Air Filter Element: Service and Repair Removal REMOVAL 1. Turn lock retainers (5) and remove fresh air inlet (2) from air cleaner housing (1). 2. Disconnect intake air temperature sensor connector (4). 3. Remove air inlet tube (5) from air cleaner housing (1). 4. Unfasten clasps (2) on sides of air cleaner housing cover. 5. Pull air cleaner cover (1) aside. 6. Remove filter element (3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal > Page 3030 7. If necessary, clean the inside of the air cleaner housing (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal > Page 3031 Air Filter Element: Service and Repair Installation INSTALLATION 1. Install new filter element. 2. Place cover over air cleaner housing. Snap clasps (2) in place. 3. Install air inlet tube (5). 4. Connect intake air temperature sensor connector (4). 5. Install fresh air inlet (2) on air cleaner housing (1) and lock retainers (5). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE PROCEDURE 1. Remove lower rear seat cushion. 2. Remove the fuel pump module cover. 3. Disconnect the electrical connector for fuel pump module. 4. Start and run engine until it stalls. 5. Attempt restarting engine until it will no longer run. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Page 3036 6. Turn ignition key to OFF position. 7. Disconnect negative battery cable. 8. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory. The scan tool must be used to erase a DTC. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications DESCRIPTION The 2.4 Liter (148 cu. in.) in-line four cylinder engine is a double over head camshaft design with mechanical lash tappets and four valves per cylinder design. This engine is NOT free-wheeling; meaning that the pistons will contact the valves in the event of a timing chain failure. The cylinders are numbered from front of the engine to the rear. The firing order is 1-3-4-2. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications SPARK PLUGS Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Removal Spark Plug: Service and Repair Removal 2.0/2.4L 1. Disconnect the negative battery cable. 2. Disconnect the electrical connectors from ignition coils. 3. Remove the ignition coil mounting bolt. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Removal > Page 3045 4. Twist the ignition coil then pull straight up. 5. Remove the spark plug using a quality socket with a rubber or foam insert. 6. Inspect the spark plug condition. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Removal > Page 3046 Spark Plug: Service and Repair Installation 2.0/2.4L Special care should be used when installing spark plugs in the cylinder head spark plug wells. Be sure the plugs do not drop into the wells, damage to the electrodes can occur. Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap. Overtightening can also damage the cylinder head. 1. To avoid cross threading, start the spark plug into the cylinder head by hand. 2. Tighten spark plugs to 17.5±2 Nm (13±2 ft. lbs.). 3. Install ignition coil on to spark plug. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Removal > Page 3047 4. Tighten coil mounting bolt. Tighten to 9 Nm (79.5 in. lbs.). 5. Connect electrical connectors and lock. 6. Connect the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Pressure Metric ................................................................................................................................................... ...................................................... 1172-1551 kPa Standard .............................................................. ............................................................................................................................................ 170-225 psi Compression should not be less than 1034 kPa (150 psi) and not vary more than 25 percent from cylinder to cylinder. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 3051 Compression Check: Testing and Inspection CYLINDER COMPRESSION PRESSURE TEST The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine reaches normal operating temperature. Select a route free from traffic and other forms of congestion, observe all traffic laws, and accelerate through the gears several times briskly. 3. Remove engine cover. 4. Disconnect coil electrical connectors and remove coils. 5. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing indicators fouled, hot, oily, etc. Record cylinder number of spark plug for future reference. 6. Disconnect injector electrical connectors. 7. Be sure throttle blade is fully open during the compression check. 8. Insert compression gauge adaptor 8116 or the equivalent, into the #1 spark plug hole in cylinder head. Connect the 0-500 psi (Blue) pressure transducer CH7059 with cable adaptors to the DRBIII(R). 9. Crank engine until maximum pressure is reached on gauge. Record this pressure as #1 cylinder pressure. 10. Repeat the previous step for all remaining cylinders. 11. Compression should not be less than 1034 kPa (150 psi) and not vary more than 25 percent from cylinder to cylinder. 12. If one or more cylinders have abnormally low compression pressures, repeat the compression test. 13. If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem in the cylinder in question. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Valve Lash Intake ................................................................................................................................................... .............................. 17 - 23 mm (0.006 - 0.009 in.) Exhaust ................................................................ .............................................................................................................. 27 - 33 mm (0.010 - 0.012 in.) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 3055 Valve Clearance: Adjustments MEASURING VALVE LASH 1. Remove engine cover. 2. Remove cylinder head cover. 3. Rotate camshaft so lobes are vertical (1). 4. Check clearance using feeler gauges. 5. Repeat for all tappets and record readings. 6. If clearance was too small, go to the clearance to small procedure.Clearance to Small. 7. If clearance was too large, go to the clearance to large procedure.Clearance to Large. Clearance to Small Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 3056 1. Remove camshafts. 2. Specification - clearance = change 3. Decrease bucket thickness by change figure. 4. Install camshafts. 5. Verify that valve lash is correct. Clearance to Large 1. Remove camshafts. 2. Clearance - specification = change. 3. Increase bucket thickness by change figure. 4. Install camshafts. 5. Verify that valve lash is correct. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Component ID: 281 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 APP SIGNAL 2 K29 20WT/BR 2 APP SENSOR GROUND 2 K400 20BR/VT 3 5 VOLT SUPPLY K854 20VT/BR 3 5 VOLT SUPPLY K858 20BR/GY 4 APP SIGNAL 1 K23 20BR/OR 5 APP SENSOR GROUND 1 K167 20BR/YL 6 5 VOLT SUPPLY K852 20BR/VT 6 5 VOLT SUPPLY F856 20YL/PK Component Location - 44 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3061 Component Location - 47 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3062 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3063 Accelerator Pedal Position Sensor: Diagrams Component ID: 281 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 APP SIGNAL 2 K29 20WT/BR 2 APP SENSOR GROUND 2 K400 20BR/VT 3 5 VOLT SUPPLY K854 20VT/BR 3 5 VOLT SUPPLY K858 20BR/GY 4 APP SIGNAL 1 K23 20BR/OR 5 APP SENSOR GROUND 1 K167 20BR/YL 6 5 VOLT SUPPLY K852 20BR/VT 6 5 VOLT SUPPLY F856 20YL/PK Component Location - 44 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3064 Component Location - 47 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3065 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3066 Accelerator Pedal Position Sensor: Description and Operation DESCRIPTION The Accelerator Pedal Position Sensor (APPS) is a variable resistor that provides the PCM with an input signal (voltage). The signal represents pedal angle position. As the position of the accelerator pedal changes, the resistance of the APPS changes. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal Accelerator Pedal Position Sensor: Service and Repair Removal REMOVAL 1. Disconnect negative battery cable. 2. Disconnect the electrical connector from the module. 3. Remove the mounting nuts. 4. Remove assembly from the mounting studs. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal > Page 3069 Accelerator Pedal Position Sensor: Service and Repair Installation INSTALLATION 1. Install APPS module. 2. Tighten the mounting nuts. 3. Connect electrical connector. 4. Connect negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations Component ID: 297 Component : SENSOR-INTAKE AIR TEMPERATURE Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 IAT SIGNAL K21 20BK/RD 2 SENSOR GROUND K915 20BR/WT Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3073 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3074 Intake Air Temperature Sensor: Diagrams Component ID: 297 Component : SENSOR-INTAKE AIR TEMPERATURE Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 IAT SIGNAL K21 20BK/RD 2 SENSOR GROUND K915 20BR/WT Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3075 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3076 Intake Air Temperature Sensor: Description and Operation DESCRIPTION The IAT Sensor is a Negative Temperature Coefficient (NTC) Sensor that provides information to the PCM regarding the temperature of the air entering the intake manifold. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Removal Intake Air Temperature Sensor: Service and Repair Removal 2.0/2.4L The sensor is located in the clean air duct. 1. Disconnect the negative battery cable. 2. Disconnect electrical connector from the sensor. 3. Remove the sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Removal > Page 3079 Intake Air Temperature Sensor: Service and Repair Installation 2.0/2.4L The sensor is in the clean air duct. 1. Install sensor. Make sure of sensor orientation. 2. Attach electrical connector to sensor. 3. Connect the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Boost Solenoid, Turbocharger > Component Information > Description and Operation Boost Solenoid: Description and Operation DESCRIPTION Turbocharged vehicles are equipped with three solenoids that are PCM controlled. They are mounted to the right shock tower. A vacuum harness connects the solenoids to their respective component. - Wastegate Actuator Solenoid - Surge Valve Actuator Solenoid - Throttle Inlet Pressure (TIP) Solenoid Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Boost Solenoid, Turbocharger > Component Information > Service and Repair > Removal Boost Solenoid: Service and Repair Removal REMOVAL 1. Remove nuts (1) securing solenoid mounting bracket to shock tower. 2. Disconnect solenoid electrical connector. 3. Disconnect vacuum harness connector from solenoid. 4. Push on solenoid lock tab (1) and slide solenoid off bracket. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Boost Solenoid, Turbocharger > Component Information > Service and Repair > Removal > Page 3085 Boost Solenoid: Service and Repair Installation INSTALLATION 1. Slide solenoid onto mounting bracket until lock tab engages. 2. Connect vacuum harness connector to solenoid. 3. Connect solenoid electrical connector. 4. Install nuts securing solenoid mounting bracket to shock tower. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Sensor-Camshaft 1/1 Position Camshaft Position Sensor: Locations Sensor-Camshaft 1/1 Position Component ID: 284 Component : SENSOR-CAMSHAFT 1/1 POSITION Connector: Name : SENSOR-CAMSHAFT 1/1 POSITION Color : BLACK # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY K857 20BR/LG 2 SENSOR GROUND K900 20DB/DG 3 CMP 1/1 SIGNAL K44 20DB Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Sensor-Camshaft 1/1 Position > Page 3090 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Sensor-Camshaft 1/1 Position > Page 3091 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Sensor-Camshaft 1/1 Position > Page 3092 Camshaft Position Sensor: Locations Sensor-Camshaft 1/2 Position Component ID: 285 Component : SENSOR-CAMSHAFT 1/2 POSITION Connector: Name : SENSOR-CAMSHAFT 1/2 POSITION Color : BLACK # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K915 20BR/WT 3 CMP 1/2 SIGNAL K441 20DB/BR Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Sensor-Camshaft 1/1 Position > Page 3093 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Sensor-Camshaft 1/1 Position Camshaft Position Sensor: Diagrams Sensor-Camshaft 1/1 Position Component ID: 284 Component : SENSOR-CAMSHAFT 1/1 POSITION Connector: Name : SENSOR-CAMSHAFT 1/1 POSITION Color : BLACK # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY K857 20BR/LG 2 SENSOR GROUND K900 20DB/DG 3 CMP 1/1 SIGNAL K44 20DB Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Sensor-Camshaft 1/1 Position > Page 3096 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Sensor-Camshaft 1/1 Position > Page 3097 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Sensor-Camshaft 1/1 Position > Page 3098 Camshaft Position Sensor: Diagrams Sensor-Camshaft 1/2 Position Component ID: 285 Component : SENSOR-CAMSHAFT 1/2 POSITION Connector: Name : SENSOR-CAMSHAFT 1/2 POSITION Color : BLACK # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K915 20BR/WT 3 CMP 1/2 SIGNAL K441 20DB/BR Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Sensor-Camshaft 1/1 Position > Page 3099 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Description Camshaft Position Sensor: Description and Operation Description DESCRIPTION The camshaft position sensors are mounted to the front and rear of the cylinder head. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Description > Page 3102 Camshaft Position Sensor: Description and Operation Operation OPERATION The PCM sends approximately 5 volts to the Hall-effect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. The input to the PCM occurs on a 5 volt output reference circuit. A ground for the sensor is provided through the sensor return circuit. The PCM identifies camshaft position by registering the change from 5 to 0 volts, as signaled from the camshaft position sensor. The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Removal Camshaft Position Sensor: Service and Repair Removal Front Camshaft Position Sensor FRONT CAMSHAFT POSITION SENSOR 1. Remove the air cleaner hose to throttle body, disconnect the inlet air temperature sensor electrical connector. 2. Disconnect negative battery cable. 3. Disconnect electrical connector from camshaft position sensor. 4. Remove camshaft position sensor mounting screws. 5. Remove sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 3105 Rear Camshaft Position Sensor REAR CAMSHAFT POSITION SENSOR 1. Disconnect negative battery cable. 2. Disconnect electrical connector at sensor. 3. Remove nut retaining heat shield. 4. Pull heat shield out to uncover sensor. 5. Remove mounting bolt. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 3106 6. Remove sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 3107 Camshaft Position Sensor: Service and Repair Installation Front Camshaft Position Sensor FRONT CAMSHAFT POSITION SENSOR 1. Lubricate sensor O-ring. 2. Install camshaft position sensor utilizing twisting motion. Make sure sensor is fully seated. Do not drive sensor into the bore with screw. This can cause sensor to be incorrectly seated causing engine to fail. Tighten sensor mounting screws to 9 Nm (79.5 in. lbs.). 3. Carefully attach electrical connector to camshaft position sensor. Installation at an angle may damage the sensor pins. 4. Install the negative battery cable. 5. Install the air cleaner to throttle body hose, connect the inlet air temperature sensor electrical connector. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 3108 Rear Camshaft Position Sensor REAR CAMSHAFT POSITION SENSOR 1. Lubricate sensor O-ring. 2. Install sensor utilizing twisting motion. Make sure sensor is fully seated. Do not drive sensor into the bore with screw. This can cause sensor to be incorrectly seated causing engine to fail. 3. Install mounting bolt and tighten to 9 Nm (79.5 in. lbs.). 4. Carefully attach electrical connector to camshaft position sensor. Fill for positive lock (click). Installation at angle may damage the sensor pins. 5. Install heat shield onto mounting stud. 6. Install heat shield retaining nut and tighten. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 3109 7. Connect the electrical connector. 8. Connect negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor Coolant Temperature Sensor/Switch (For Computer): Technical Service Bulletins Engine Controls MIL On/DTC P0116/ECT Sensor NUMBER: 18-039-06 GROUP: Vehicle Performance DATE: December 6, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES FOR StarSCAN. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 7.02 SP2 OR HIGHER FOR THIS BULLETIN. SUBJECT: Flash: MIL Illumination DTC P0116 - Engine Coolant Temperature Sensor Performance OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) and the Transmission Control Module (1CM) with new software. CAUTION: VEHICLES EQUIPPED WITH A CVT TRANSMISSION MUST HAVE THE TRANSMISSION CONTROL MODULE (TCM) CHECKED FOR THE LATEST SOFTWARE LEVEL WHENEVER THE PCM SOFTWARE IS UPGRADED. IF NEWER TCM SOFTWARE IS AVAILABLE, IT MUST BE INSTALLED. MODELS: 2007 (PM) Caliber 2007 (MK49) Compass NOTE: This bulletin applies to PM/MK models equipped with a 1.8L, 2.0L or 2.4L gasoline engine (Sales Code EBA, ECN or ED3) and block heater (Sales Code NHK) built before November 20, 2006 (MDH 1120XX). NOTE: If an aftermarket or MOPAR accessory block heater is installed, the same conditions may apply. SYMPTOM/CONDITION: Some customers may experience MIL illumination after using the block heater. No other symptoms will be experienced. The technician may find the following DTC's: ^ P0116 - ENGINE COOLANT TEMPERATURE SENSOR PERFORMANCE DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If MIL illumination with DTC P0116 is present, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 3114 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING **STEP 5n and/or 8h**. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 7.02 SP2 software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. PM/MK Models equipped with a CVT must have the TCM reprogrammed as follows: 6. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. 7. Is the TCM part number recorded in step 6e above, the same as the new p/n shown on the "Flash File List" screen? a. Yes >> No further action is necessary. Proceed to Step 9. b. No >> the TCM will require flash reprogramming, proceed to Step 8. 8. Flash reprogram the TCM as follows: a. From the "Flash File List" screen, select "Download to Scantool". b. Select "Close" after the download is complete, then select "Back". c. Highlight the listed calibration. d. Select "Update Controller". Follow on screen instructions. e. When the update is complete, select "OK". f. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. g. Turn the ignition switch to the OFF position for no less than 15 seconds. h. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 3115 CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the TCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. ** NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 9. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Sensor-Engine Coolant Temperature 1 Coolant Temperature Sensor/Switch (For Computer): Locations Sensor-Engine Coolant Temperature 1 Component ID: 290 Component : SENSOR-ENGINE COOLANT TEMPERATURE 1 Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE 1 Color : DK. GRAY # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 SENSOR GROUND K900 20DB/DG 2 ECT 1 SIGNAL K2 20VT/OR Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Sensor-Engine Coolant Temperature 1 > Page 3118 Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Sensor-Engine Coolant Temperature 1 > Page 3119 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Sensor-Engine Coolant Temperature 1 > Page 3120 Coolant Temperature Sensor/Switch (For Computer): Locations Sensor-Engine Coolant Temperature 2 Component ID: 291 Component : SENSOR-ENGINE COOLANT TEMPERATURE 2 Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE 2 Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 SENSOR GROUND K915 20BR/WT 2 ECT 2 SIGNAL K222 20BR/YL Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Sensor-Engine Coolant Temperature 1 > Page 3121 Component Location - 15 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Sensor-Engine Coolant Temperature 1 > Page 3122 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Sensor-Engine Coolant Temperature 1 Coolant Temperature Sensor/Switch (For Computer): Diagrams Sensor-Engine Coolant Temperature 1 Component ID: 290 Component : SENSOR-ENGINE COOLANT TEMPERATURE 1 Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE 1 Color : DK. GRAY # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 SENSOR GROUND K900 20DB/DG 2 ECT 1 SIGNAL K2 20VT/OR Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Sensor-Engine Coolant Temperature 1 > Page 3125 Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Sensor-Engine Coolant Temperature 1 > Page 3126 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Sensor-Engine Coolant Temperature 1 > Page 3127 Coolant Temperature Sensor/Switch (For Computer): Diagrams Sensor-Engine Coolant Temperature 2 Component ID: 291 Component : SENSOR-ENGINE COOLANT TEMPERATURE 2 Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE 2 Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 SENSOR GROUND K915 20BR/WT 2 ECT 2 SIGNAL K222 20BR/YL Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Sensor-Engine Coolant Temperature 1 > Page 3128 Component Location - 15 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Sensor-Engine Coolant Temperature 1 > Page 3129 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Component ID: 287 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 CKP SENSOR 5 VOLT SUPPLY K853 20DB/BR 2 CKP SENSOR SIGNAL K24 20BR/LB 3 CKP SENSOR GROUND K925 20DB/WT Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3133 Component Location - 19 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3134 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3135 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20LB/BR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3136 Component Location - 16 Component Location - 19 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3137 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3138 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3139 Crankshaft Position Sensor: Diagrams Component ID: 287 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 CKP SENSOR 5 VOLT SUPPLY K853 20DB/BR 2 CKP SENSOR SIGNAL K24 20BR/LB 3 CKP SENSOR GROUND K925 20DB/WT Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3140 Component Location - 19 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3141 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3142 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20LB/BR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3143 Component Location - 16 Component Location - 19 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3144 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3145 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description DESCRIPTION The crankshaft position sensor mounts to the rear of the engine block near the transmission. The PCM uses the Crankshaft Position sensor to calculate the following: - Engine RPM - TDC number 1 and 4 - Ignition coil synchronization - Injector synchronization - Camshaft-to-crankshaft misalignment (Timing belt skipped 1 tooth or more diagnostic trouble code). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 3148 Crankshaft Position Sensor: Description and Operation Operation OPERATION The PCM sends approximately 5 volts to the Hall-effect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. A ground for the sensor is provided through the sensor return circuit. The input to the PCM occurs on a 5 volt output reference circuit that operates as follows: The Hall-effect sensor contains a powerful magnet. As the magnetic field passes over the dense portion of the counterweight, the 5-volt signal is pulled to ground (0.3 volts) through a transistor in the sensor. When the magnetic field passes over the notches in the crankshaft counterweight, the magnetic field turns off the transistor in the sensor, causing the PCM to register the 5-volt signal. The PCM identifies crankshaft position by registering the change from 5 to 0 volts, as signaled from the Crankshaft Position sensor (2). The PCM determines which cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. The #8 crankshaft counterweight has a target ring with 32 teeth and notches (1), including one long reference tooth and notch. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Removal Crankshaft Position Sensor: Service and Repair Removal 2.0/2.4L The Crankshaft Position Sensor is in the rear of the engine block near the transmission. If vehicle is All Wheel Drive the Power Transfer Unit must be removed. 1. Disconnect the negative battery cable. 2. Raise vehicle and support. 3. Remove heat shield retaining bolt. 4. Remove heat shield. 5. Unlock and disconnect the electrical connector to the crankshaft position sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Removal > Page 3151 6. Remove the crankshaft position sensor bolt. 7. Remove the sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Removal > Page 3152 Crankshaft Position Sensor: Service and Repair Installation 2.0/2.4L 1. Check O-ring for damage and lubricate the O-ring with engine oil before installing sensor. 2. Use a twisting motion when installing the sensor. 3. Install and tighten the crankshaft position sensor bolt and tighten to 9 Nm (79.5 in. lbs.). 4. Connect and lock the electrical connector to the crankshaft position sensor. 5. Install heat shield and retaining bolt. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Removal > Page 3153 If vehicle is All Wheel Drive the Power Transfer Unit must be installed. 6. Lower vehicle. 7. Connect the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations Data Link Connector: Locations Component ID: 51 Component : DATA LINK CONNECTOR Connector: Name : DATA LINK CONNECTOR Color : BLACK # of pins : 16 Pin Description Circuit 1-2-3-4 GROUND Z11 20BK/BR 5 GROUND Z11 20BK/BR 6 DIAGNOSTIC CAN C (+) D72 20WT/TN 7 SCI TRANSMIT D21 20WT/BR 8-9-10 - 11 - 12 - 13 - 14 DIAGNOSTIC CAN C (-) D71 20WT/DB 15 - 16 FUSED B(+) A933 20RD/LG Component Location - 37 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 3157 Fig. 37 Component Location - 44 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 3158 Component Location - 47 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 3159 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions Data Link Connector: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: Provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3162 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3163 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3164 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3165 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3166 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3167 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3168 5. Release the Secondary Terminal Lock, if required (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3169 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3170 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3171 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3172 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3173 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3174 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3175 Data Link Connector: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3176 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3177 STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3178 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3179 Data Link Connector: Connector Views Component ID: 51 Component : DATA LINK CONNECTOR Connector: Name : DATA LINK CONNECTOR Color : BLACK # of pins : 16 Pin Description Circuit 1-2-3-4 GROUND Z11 20BK/BR 5 GROUND Z11 20BK/BR 6 DIAGNOSTIC CAN C (+) D72 20WT/TN 7 SCI TRANSMIT D21 20WT/BR 8-9-10 - 11 - 12 - 13 - 14 DIAGNOSTIC CAN C (-) D71 20WT/DB 15 - 16 FUSED B(+) A933 20RD/LG Component Location - 37 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3180 Fig. 37 Component Location - 44 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3181 Component Location - 47 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3182 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Description and Operation > Description Data Link Connector: Description and Operation Description DESCRIPTION The Data Link Connector (DLC) (1) is a 16-way molded plastic connector that is part of the instrument panel wire harness. This connector is located at the lower edge of the instrument panel, outboard of the steering column. The connector insulator is retained by integral snap features within a rectangular cutout in a mounting bracket integral to the lower instrument panel and inboard of the inside hood release on the inner cowl side trim. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Description and Operation > Description > Page 3185 Data Link Connector: Description and Operation Operation OPERATION The Data Link Connector (DLC) is an industry-standard 16-way connector that permits the connection of a diagnostic scan tool to the Controller Area Network (CAN) data bus for interfacing with, configuring, and retrieving Diagnostic Trouble Code (DTC) data from the electronic modules that reside on the data bus network of the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor Engine Control Module: Technical Service Bulletins Engine Controls - MIL On/DTC P0116/ECT Sensor NUMBER: 18-039-06 GROUP: Vehicle Performance DATE: December 6, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES FOR StarSCAN. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 7.02 SP2 OR HIGHER FOR THIS BULLETIN. SUBJECT: Flash: MIL Illumination DTC P0116 - Engine Coolant Temperature Sensor Performance OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) and the Transmission Control Module (1CM) with new software. CAUTION: VEHICLES EQUIPPED WITH A CVT TRANSMISSION MUST HAVE THE TRANSMISSION CONTROL MODULE (TCM) CHECKED FOR THE LATEST SOFTWARE LEVEL WHENEVER THE PCM SOFTWARE IS UPGRADED. IF NEWER TCM SOFTWARE IS AVAILABLE, IT MUST BE INSTALLED. MODELS: 2007 (PM) Caliber 2007 (MK49) Compass NOTE: This bulletin applies to PM/MK models equipped with a 1.8L, 2.0L or 2.4L gasoline engine (Sales Code EBA, ECN or ED3) and block heater (Sales Code NHK) built before November 20, 2006 (MDH 1120XX). NOTE: If an aftermarket or MOPAR accessory block heater is installed, the same conditions may apply. SYMPTOM/CONDITION: Some customers may experience MIL illumination after using the block heater. No other symptoms will be experienced. The technician may find the following DTC's: ^ P0116 - ENGINE COOLANT TEMPERATURE SENSOR PERFORMANCE DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If MIL illumination with DTC P0116 is present, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 3190 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING **STEP 5n and/or 8h**. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 7.02 SP2 software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. PM/MK Models equipped with a CVT must have the TCM reprogrammed as follows: 6. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. 7. Is the TCM part number recorded in step 6e above, the same as the new p/n shown on the "Flash File List" screen? a. Yes >> No further action is necessary. Proceed to Step 9. b. No >> the TCM will require flash reprogramming, proceed to Step 8. 8. Flash reprogram the TCM as follows: a. From the "Flash File List" screen, select "Download to Scantool". b. Select "Close" after the download is complete, then select "Back". c. Highlight the listed calibration. d. Select "Update Controller". Follow on screen instructions. e. When the update is complete, select "OK". f. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. g. Turn the ignition switch to the OFF position for no less than 15 seconds. h. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 3191 CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the TCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. ** NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 9. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 3192 Engine Control Module: Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 3193 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 3194 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 3195 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3196 Engine Control Module: Locations Component ID: 160 Component : MODULE-POWERTRAIN CONTROL Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK # of pins : 58 Qualifier : (GAS) Pin Description Circuit 1 FUSED MAIN RELAY OUTPUT F342 14BR/DG 2 GROUND Z925 16BK/YL 3 FUSED MAIN RELAY OUTPUT F342 14BR/DG 4 GROUND Z925 16BK/YL 5-6-- 7 O2 1/2 HEATER CONTROL K299 20BR/RD 8-9-10 - 11 - 12 - 13 S/C SWITCH GROUND V937 20VT/BR 14 - 15 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 16 FUSED B(+) A931 20RD/WT 17 - 18 - 19 FUEL PUMP CONTROL K31 20BR 20 O2 1/2 RETURN K904 20DB/DG 21 O2 1/2 SIGNAL K141 20DB/YL 22 5 VOLT SUPPLY K858 20BR/GY 23 5 VOLT SUPPLY F856 20YL/PK 24 - 25 STARTER CONTROL T752 20DG/OR 26 S/C SIGNAL 2 V72 20OR/VT 27 S/C SIGNAL 1 V71 20VT/OR 28 - 29 - 30 SENSOR GROUND K914 20DB/PK 31 - 32 BRAKE SIGNAL 1 B15 20DG/WT 33 - 34 APP SENSOR GROUND 2 K400 20BR/VT Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3197 35 EVAP PURGE RETURN K70 20DB/BR 36 APP SENSOR GROUND 1 K167 20BR/YL 37 START ENABLE F963 20PK/DB 38 VEHICLE SPEED SIGNAL K75 20DB/OR 39 EVAP PURGE CONTROL K52 20DB/WT 40 - 41 CAN C BUS (+) D65 20WT/BK 42 - 43 - 44 - 45 - - 46 - 47 ESM SIGNAL K107 20VT/WT 48 APP SIGNAL 2 K29 20WT/BR 49 APP SIGNAL 1 K23 20BR/OR 50 CLUTCH INTERLOCK SIGNAL T141 20YL/RD 51 - 52 BRAKE SIGNAL 2 B16 20LB/DG 53 GEN SENSE A804 20RD/GY 54 CAN C BUS (-) D64 20WT/LB 55 - 56 - 57 - 58 MAIN RELAY CONTROL K51 20BR/LG Component Location - 8 Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3198 Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3199 Connector: Name : MODULE-POWERTRAIN CONTROL C2 Color : BLACK # of pins : 96 Qualifier : (GAS) Pin Description Circuit 1 ETC MOTOR (+) K124 20DB/GY 2-3-4-- Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3200 5-6 A/C COMPRESSOR CONTROL C27 20LB/WT 7-8 IAT SIGNAL K21 20BK/RD 9-10 - 11 ECT 2 SIGNAL K222 20BR/YL 12 - 13 - 14 - 15 - 16 - 17 - 18 - 19 - 20 - 21 INJECTOR 3 CONTROL K13 20BR/LB 22 INJECTOR 4 CONTROL K14 20BR/TN 23 INJECTOR 1 CONTROL K11 20YL/BR 24 INJECTOR 2 CONTROL K12 20BR/DB 25 ETC MOTOR (-) K126 20DB/LG 26 - 27 MFV CONTROL K601 20BR/VT 28 - 29 - 30 - 31 - 32 - 33 O2 1/1 SIGNAL K41 20BK/DG 34 - 35 - - 36 O2 1/1 RETURN K902 20BR/DG 37 EOT SIGNAL G24 20VT/BR 38 CMP 1/2 SIGNAL K441 20DB/BR 39 - 40 - 41 5 VOLT SUPPLY F855 20PK/YL 42 5 VOLT SUPPLY K857 20BR/LG 43 - 44 - 45 - 46 - 47 - 48 - 49 O2 1/1 HEATER CONTROL K99 20BR/OR 50 - 51 GEN FIELD CONTROL K20 20BR/GY 52 - 53 - 54 - 55 - 56 - 57 CMP 1/1 SIGNAL K44 20DB 58 SENSOR GROUND K915 20BR/WT 59 - 60 - 61 - 62 TP SENSOR GROUND K922 20BR 63 TP SIGNAL 2 K122 20DG/BR 64 TP SIGNAL 1 K22 20OR/BR 65 KS RETURN K942 20WT/BR 66 - - 67 - 68 - 69 - 70 CMP 1/1 CONTROL K76 20LB/WT Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3201 71 - 72 CMP 1/2 CONTROL K276 20DB/WT 73 COIL 4 CONTROL K15 18GY/DB 74 COIL 3 CONTROL K18 18DB/OR 75 COIL 2 CONTROL K17 18DB/TN 76 COIL 1 CONTROL K19 18DG/LB 77 - 78 - 79 CKP SIGNAL K24 20LB/BR 80 - 81 - - 82 SENSOR GROUND K900 20DB/DG 83 ECT 1 SIGNAL K2 20VT/OR 84 MFV SIGNAL K602 20YL/DB 85 MAP SIGNAL K1 20VT/LB 86 EOP SIGNAL G6 20VT/GY 87 - 88 KS SIGNAL K42 20LG/DB 89 - 90 - 91 - 92 - 93 - 94 - 95 - 96 - Component Location - 8 Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3202 Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3203 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: Provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3206 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3207 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3208 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3209 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3210 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3211 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3212 5. Release the Secondary Terminal Lock, if required (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3213 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3214 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3215 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3216 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3217 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3218 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3219 Engine Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3220 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3221 STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3222 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3223 Engine Control Module: Connector Views Component ID: 160 Component : MODULE-POWERTRAIN CONTROL Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK # of pins : 58 Qualifier : (GAS) Pin Description Circuit 1 FUSED MAIN RELAY OUTPUT F342 14BR/DG 2 GROUND Z925 16BK/YL 3 FUSED MAIN RELAY OUTPUT F342 14BR/DG 4 GROUND Z925 16BK/YL 5-6-- 7 O2 1/2 HEATER CONTROL K299 20BR/RD 8-9-10 - 11 - 12 - 13 S/C SWITCH GROUND V937 20VT/BR 14 - 15 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 16 FUSED B(+) A931 20RD/WT 17 - 18 - 19 FUEL PUMP CONTROL K31 20BR 20 O2 1/2 RETURN K904 20DB/DG 21 O2 1/2 SIGNAL K141 20DB/YL 22 5 VOLT SUPPLY K858 20BR/GY 23 5 VOLT SUPPLY F856 20YL/PK 24 - 25 STARTER CONTROL T752 20DG/OR 26 S/C SIGNAL 2 V72 20OR/VT 27 S/C SIGNAL 1 V71 20VT/OR 28 - 29 - 30 SENSOR GROUND K914 20DB/PK 31 - 32 BRAKE SIGNAL 1 B15 20DG/WT 33 - 34 APP SENSOR GROUND 2 K400 20BR/VT Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3224 35 EVAP PURGE RETURN K70 20DB/BR 36 APP SENSOR GROUND 1 K167 20BR/YL 37 START ENABLE F963 20PK/DB 38 VEHICLE SPEED SIGNAL K75 20DB/OR 39 EVAP PURGE CONTROL K52 20DB/WT 40 - 41 CAN C BUS (+) D65 20WT/BK 42 - 43 - 44 - 45 - - 46 - 47 ESM SIGNAL K107 20VT/WT 48 APP SIGNAL 2 K29 20WT/BR 49 APP SIGNAL 1 K23 20BR/OR 50 CLUTCH INTERLOCK SIGNAL T141 20YL/RD 51 - 52 BRAKE SIGNAL 2 B16 20LB/DG 53 GEN SENSE A804 20RD/GY 54 CAN C BUS (-) D64 20WT/LB 55 - 56 - 57 - 58 MAIN RELAY CONTROL K51 20BR/LG Component Location - 8 Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3225 Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3226 Connector: Name : MODULE-POWERTRAIN CONTROL C2 Color : BLACK # of pins : 96 Qualifier : (GAS) Pin Description Circuit 1 ETC MOTOR (+) K124 20DB/GY 2-3-4-- Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3227 5-6 A/C COMPRESSOR CONTROL C27 20LB/WT 7-8 IAT SIGNAL K21 20BK/RD 9-10 - 11 ECT 2 SIGNAL K222 20BR/YL 12 - 13 - 14 - 15 - 16 - 17 - 18 - 19 - 20 - 21 INJECTOR 3 CONTROL K13 20BR/LB 22 INJECTOR 4 CONTROL K14 20BR/TN 23 INJECTOR 1 CONTROL K11 20YL/BR 24 INJECTOR 2 CONTROL K12 20BR/DB 25 ETC MOTOR (-) K126 20DB/LG 26 - 27 MFV CONTROL K601 20BR/VT 28 - 29 - 30 - 31 - 32 - 33 O2 1/1 SIGNAL K41 20BK/DG 34 - 35 - - 36 O2 1/1 RETURN K902 20BR/DG 37 EOT SIGNAL G24 20VT/BR 38 CMP 1/2 SIGNAL K441 20DB/BR 39 - 40 - 41 5 VOLT SUPPLY F855 20PK/YL 42 5 VOLT SUPPLY K857 20BR/LG 43 - 44 - 45 - 46 - 47 - 48 - 49 O2 1/1 HEATER CONTROL K99 20BR/OR 50 - 51 GEN FIELD CONTROL K20 20BR/GY 52 - 53 - 54 - 55 - 56 - 57 CMP 1/1 SIGNAL K44 20DB 58 SENSOR GROUND K915 20BR/WT 59 - 60 - 61 - 62 TP SENSOR GROUND K922 20BR 63 TP SIGNAL 2 K122 20DG/BR 64 TP SIGNAL 1 K22 20OR/BR 65 KS RETURN K942 20WT/BR 66 - - 67 - 68 - 69 - 70 CMP 1/1 CONTROL K76 20LB/WT Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3228 71 - 72 CMP 1/2 CONTROL K276 20DB/WT 73 COIL 4 CONTROL K15 18GY/DB 74 COIL 3 CONTROL K18 18DB/OR 75 COIL 2 CONTROL K17 18DB/TN 76 COIL 1 CONTROL K19 18DG/LB 77 - 78 - 79 CKP SIGNAL K24 20LB/BR 80 - 81 - - 82 SENSOR GROUND K900 20DB/DG 83 ECT 1 SIGNAL K2 20VT/OR 84 MFV SIGNAL K602 20YL/DB 85 MAP SIGNAL K1 20VT/LB 86 EOP SIGNAL G6 20VT/GY 87 - 88 KS SIGNAL K42 20LG/DB 89 - 90 - 91 - 92 - 93 - 94 - 95 - 96 - Component Location - 8 Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3229 Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3230 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description Engine Control Module: Description and Operation Description PCM Ground PCM GROUND Ground is provided through multiple pins of the PCM connector. Depending on the vehicle there may be as many as two different ground pins. There are power grounds and sensor grounds. The power grounds are used to control the ground side relays, solenoids, ignition coil or injectors. The signal ground is used for any input that uses sensor return for ground, and the ground side of any internal processing component. The PCM case is shielded to prevent RFI and EMI. The PCM case is grounded and must be firmly attached to a good, clean body ground. Internally all grounds are connected together, however there is noise suppression on the sensor ground. For EMI and RFI protection the housing and cover are also grounded separately from the ground pins. Sensor Return - PCM Input SENSOR RETURN - PCM INPUT The sensor return circuit provides a low electrical noise ground reference for all of the systems sensors. The sensor return circuit connects to internal ground circuits within the Powertrain Control Module (PCM). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description > Page 3233 Engine Control Module: Description and Operation Operation Powertrain Control Module POWERTRAIN CONTROL MODULE The PCM receives input signals from various switches and sensors that are referred to as PCM Inputs. Based on these inputs, the PCM adjusts various engine and vehicle operations through devices that are referred to as PCM Outputs. NOTE: PCM Inputs: - Air Conditioning Controls - Battery Voltage - Brake Switch - Camshaft Position Sensor - Clutch Upstop Switch - Clutch Interlock - Crankshaft Position Sensor - Engine Coolant Temperature Sensor - Fuel Level Sensor (Bus message) - Ignition Switch - Intake Air Temperature Sensor - Knock Sensor - Evaporative System Integrity Monitor - Manifold Absolute Pressure (MAP) Sensor - Oil Pressure Switch - Oxygen Sensors - Power Steering Pressure Switch - Speed Control Switches - Vehicle Speed Sensor (MTX-equipped models) NOTE: PCM Outputs: - Air Conditioning Clutch Relay - Charging Indicator Lamp (Bus Message) - Proportional Purge Solenoid - Fuel Injectors - Generator Field - Ignition Coils - Malfunction Indicator (Check Engine) Lamp (Bus Message) - Manifold Flow Valve - Oxygen Sensors Heater Controls - Variable Valve Timing - Vehicle Speed (Manual Transmission) Based on inputs it receives, the PCM adjusts fuel injector pulse width, idle speed, ignition spark advance, ignition coil dwell and EVAP canister purge operation. The PCM also determines the appropriate transmission shift schedule and shift points, depending on the present operating conditions and driver demand. The PCM regulates the cooling fan, air conditioning and speed control systems. The PCM changes generator charge rate by adjusting the Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description > Page 3234 generator field. The PCM also performs diagnostics. The PCM adjusts injector pulse width (air-fuel ratio) based on the following inputs. - Battery voltage - Coolant temperature - Exhaust gas content (oxygen sensor) - Engine speed (crankshaft position sensor) - Intake air temperature - Manifold absolute pressure - Throttle position The PCM adjusts ignition timing based on the following inputs. - Coolant temperature - Engine speed (crankshaft position sensor) - Knock sensor - Manifold absolute pressure - Throttle position - Transmission gear selection (park/neutral switch) - Intake air temperature The PCM also adjusts engine idle speed through the idle air control motor based on the following inputs. - Air conditioning sense - Battery voltage - Brake switch - Coolant temperature - Engine speed (crankshaft position sensor) - Engine run time - Manifold absolute pressure - Power steering pressure switch - Throttle position - Transmission gear selection (park/neutral switch) - Vehicle distance (speed) The camshaft position sensor and crankshaft position sensor signals are sent to the PCM. If the PCM does not receive the signal within approximately 1 second of engine cranking, it deactivates the fuel pump. When these are deactivated, power is shut off to the fuel injectors, ignition coils, oxygen sensor heating elements and fuel pump. The PCM contains a voltage converter that changes battery voltage to a regulated 5 volt direct current to power the camshaft position sensor, crankshaft position sensor, manifold absolute pressure sensor, throttle position sensor, A/C pressure switch, A/C pressure transducer, and vehicle speed sensor. 5 Volt Supply - PCM Output 5 VOLT SUPPLY - PCM OUTPUT The PCM supplies 5 volts to the following sensors: - A/C pressure transducer - Ambient Temperature sensor - Battery temperature - Camshaft Position Sensor (NGC) - Crankshaft Position Sensor (NGC) - Engine coolant temperature sensor - Inlet Air Temperature Sensor - Knock sensor - Linear EGR solenoid (if equipped) - Manifold absolute pressure sensor - Oil Pressure Switch Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM/SKREEM Programming Engine Control Module: Testing and Inspection PCM/ECM/SKREEM Programming PCM/ECM/SKREEM PROGRAMMING NOTE: Before replacing the Powertrain Control Module (PCM) or Engine Control Module (ECM), be certain to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most PCM/ECM driver/control circuit failures are caused by internal component failures (i.e. relays and solenoids) and shorted circuits (i.e. pull-ups, drivers, and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has been set. When a PCM, or ECM, and the Sentry Key REmote Entry Module (SKREEM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: 1. Program the new PCM or ECM. 2. Program the new SKREEM (also sometimes referred to as the Wireless Control Module or WCM). 3. Replace all ignition keys and program them into the new SKREEM/WCM. PROGRAMMING THE SKREEM The SKIS Secret Key is an ID code that is unique to each SKREEM/WCM. This code is programmed and stored in the SKREEM/WCM, the PCM/ECM, and each ignition key transponder chip. When the PCM or SKREEM/WCM is replaced, it is necessary to program the Secret Key into the new module using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool for "PCM Replaced" or "WCM Replaced" under "Miscellaneous Functions" for the "WCM/Wireless Control Module" menu item as appropriate. NOTE: If the PCM/ECM and the SKREEM/WCM are replaced at the same time, all vehicle ignition keys will need to be replaced and new keys programmed into the new SKREEM/WCM. NOTE: Programming the PCM/ECM or SKREEM is done using a diagnostic scan tool and a PIN to enter secure access mode. If eight attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. (Ensure all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary). PROGRAMMING IGNITION KEYS TO THE SKREEM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKREEM/WCM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKREEM/WCM. To program ignition keys into the SKREEM/WCM, follow the programming steps outlined in the diagnostic scan tool for PROGRAM IGNITION KEYS OR KEY FOBS under MISCELLANEOUS FUNCTIONS for the WCM/WIRELESS CONTROL MODULE menu item. NOTE: A maximum of eight keys can be learned to each SKREEM. Once a key is learned to a SKREEM, that key has acquired the Secret Key for that SKREEM and cannot be transferred to any other SKREEM or vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: - Programming Not Attempted - The scan tool attempts to read the programmed key status and there are no keys programmed into SKREEM memory. - Programming Key Failed (Possible Used Key From Wrong Vehicle) - SKREEM is unable to program an ignition key transponder due to one of the following: - The ignition key transponder is faulty. - The ignition key transponder is or has been already programmed to another vehicle. - 8 Keys Already Learned, Programming Not Done - The SKREEM transponder ID memory is full. - Learned Key In Ignition - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKREEM memory. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM/SKREEM Programming > Page 3237 Engine Control Module: Testing and Inspection Pinion Factor Setting PINION FACTOR SETTING NOTE: This procedure must be performed if the PCM has been replaced with a NEW or replacement unit. Failure to perform this procedure will result in an inoperative or improperly calibrated speedometer. The vehicle speed readings for the speedometer are taken from the output speed sensor. The PCM must be calibrated to the different combinations of equipment (final drive and tires) available. Pinion Factor allows the technician to set the Powertrain Control Module initial setting so that the speedometer readings will be correct. To properly read and/or reset the Pinion Factor, it is necessary to use a scan tool. 1. Plug the scan tool into the diagnostic connector located under the instrument panel. 2. Select the Transmission menu. 3. Select the Miscellaneous menu. 4. Select Pinion Factor. Then follow the instructions on the scan tool screen. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal Engine Control Module: Service and Repair Removal REMOVAL USE THE SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM) WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (VIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. To avoid possible voltage spike damage to PCM, ignition key must be off, and negative battery cable must be disconnected before unplugging PCM connectors. 1. Disconnect negative battery cable. 2. Unlock and disconnect the electrical connectors from PCM. 3. Remove the air cleaner box. 4. Remove the three mounting bolts. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal > Page 3240 5. Tip module out and remove from bracket. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal > Page 3241 Engine Control Module: Service and Repair Installation INSTALLATION USE THE SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM) WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (VIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. 1. Tip module into bracket. 2. Install three mounting bolts and tighten to 9 Nm (80 in. lbs.) torque. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal > Page 3242 3. Check pins in electrical connectors for damage. Repair as necessary. 4. Connect electrical connectors and lock. 5. Install air cleaner box. 6. Connect negative battery cable. 7. Use the scan tool to reprogram new PCM with vehicles original Identification Number (VIN) and original vehicle mileage. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions Information Bus: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: Provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3247 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3248 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3249 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3250 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3251 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3252 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3253 5. Release the Secondary Terminal Lock, if required (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3254 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3255 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3256 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3257 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3258 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3259 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3260 Information Bus: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3261 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3262 STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3263 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3264 Information Bus: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-18-02 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3265 8w-18-03 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3266 8w-18-04 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3267 8w-18-05 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3268 8w-18-06 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3269 8w-18-07 Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Component ID: 299 Component : SENSOR-KNOCK Connector: Name : SENSOR-KNOCK Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 KS SIGNAL K42 20LG/DB 2 KS RETURN K942 20WT/BR Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3273 Component Location - 15 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3274 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3275 Knock Sensor: Diagrams Component ID: 299 Component : SENSOR-KNOCK Connector: Name : SENSOR-KNOCK Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 KS SIGNAL K42 20LG/DB 2 KS RETURN K942 20WT/BR Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3276 Component Location - 15 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3277 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Description Knock Sensor: Description and Operation Description DESCRIPTION The knock sensor is bolted to the cylinder block. The knock sensor is designed to detect engine vibration that is caused by detonation or preignition. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Description > Page 3280 Knock Sensor: Description and Operation Operation OPERATION When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives as an input the knock sensor voltage signal. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, ignition timing retard is allowed. Ignition timing is retarded uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard ignition timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except WOT. The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening affects knock sensor performance, possibly causing improper spark control. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Removal Knock Sensor: Service and Repair Removal 2.0/2.4L The knock sensor bolts into the side of the cylinder block in front of the starter under the intake manifold. 1. Disconnect the negative battery cable. 2. Remove the bolt holding the knock sensor. 3. Remove sensor with electrical connector attached. 4. Disconnect electrical connector from knock sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Removal > Page 3283 5. Remove the knock sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Removal > Page 3284 Knock Sensor: Service and Repair Installation 2.0/2.4L The knock sensor bolts into the side of the cylinder block in front of the starter under the intake manifold. 1. Attach electrical connector to knock sensor. 2. Install knock sensor. Tighten knock sensor bolt to 22 Nm (195 in. lbs.). Over or under tightening effects knock sensor performance, possibly causing improper spark control. 3. Connect the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Main Relay is located in the Fuse/Relay block. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3288 Main Relay (Computer/Fuel System): Diagrams Component ID: 182 Component : RELAY-MAIN Connector: Name : RELAY-MAIN Color : # of pins : 0 B6 FUSED B(+) A14 12RD/YL B7 MAIN RELAY OUTPUT K542 12BR/WT B8 - B9 FUSED B(+) A14 12RD/YL B10 MAIN RELAY CONTROL K51 20BR/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations Component ID: 300 Component : SENSOR-MAP Connector: Name : SENSOR-MAP Color : BLACK # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 MAP SIGNAL K1 20VT/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY K857 20BR/LG Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3292 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3293 Manifold Pressure/Vacuum Sensor: Diagrams Component ID: 300 Component : SENSOR-MAP Connector: Name : SENSOR-MAP Color : BLACK # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 MAP SIGNAL K1 20VT/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY K857 20BR/LG Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3294 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Description Manifold Pressure/Vacuum Sensor: Description and Operation Description DESCRIPTION The MAP sensor mounts to the intake manifold. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Description > Page 3297 Manifold Pressure/Vacuum Sensor: Description and Operation Operation OPERATION The MAP serves as a PCM input, using a silicon based sensing unit, to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When MAP equals Barometric pressure, the pulse width will be at maximum. Also like the cam and crank sensors, a 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5 volt and full scale is 4.5 volt. For a pressure swing of 0 - 15 psi the voltage changes 4.0 volt. The sensor is supplied a regulated 4.8 to 5.1 volts to operate the sensor. Like the cam and crank sensors ground is provided through the sensor return circuit. The MAP sensor input is the number one contributor to pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or is it in Denver at 5000 feet above sea level, because the air density changes with altitude. It will also help to correct for varying weather conditions. If a hurricane was coming through the pressure would be very, very low or there could be a real fair weather, high pressure area. This is important because as air pressure changes the barometric pressure changes. Barometric pressure and altitude have a direct inverse correlation, as altitude goes up barometric goes down. The first thing that happens as the key is rolled on, before reaching the crank position, the PCM powers up, comes around and looks at the MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure relative to altitude. Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key on. The difference between current and what it was at key on is manifold vacuum. During key On (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring known good sensor in your work area. As the altitude increases the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key On the barometric pressure needs to be updated. Any time the PCM sees Wide Open throttle, based upon TPS angle and RPM it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively. The PCM uses the MAP sensor to aid in calculating the following: - Barometric pressure - Engine load - Manifold pressure - Injector pulse-width - Spark-advance programs - Shift-point strategies (F4AC1 transmissions only, via the PCI bus) - Idle speed - Decel fuel shutoff The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 88 kPa (26 in. Hg). Barometric pressure is the pressure exerted by the atmosphere upon an object. At sea level on a standard day, no storm, barometric pressure is 101 kPa (29.92 in. Hg). For every 30.5 meters (100 feet) of altitude barometric pressure drops .33 kPa (0.10 in. Hg). If a storm goes through it can either add, high pressure, or decrease, low pressure, from what should be present for that altitude. You should make a habit of knowing what the average pressure and corresponding barometric pressure is for your area. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal Manifold Pressure/Vacuum Sensor: Service and Repair Removal 2.0/2.4L 1. Remove the air cleaner cover. 2. Disconnect the negative battery cable. 3. Disconnect the electrical connector from the MAP sensor. 4. Remove the screws from the MAP sensor. 5. Remove the MAP sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 3300 Manifold Pressure/Vacuum Sensor: Service and Repair Installation 2.0/2.4L 1. Make sure that the manifold is clean. 2. Install sensor to manifold. 3. Tighten screw. 4. Connect the electrical connector to the sensor. 5. Connect the negative battery cable. 6. Install the air cleaner cover. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 Oxygen Sensor: Locations Sensor - Oxygen 1/1 Component ID: 304 Component : SENSOR-OXYGEN 1/1 Connector: Name : SENSOR-OXYGEN 1/1 Color : GRAY # of pins : 4 Qualifier : (GAS) Pin Description Circuit 1 GROUND Z916 18BK 2 O2 1/1 HEATER CONTROL K99 20BR/OR 3 O2 1/1 RETURN K902 20BR/DG 4 O2 1/1 SIGNAL K41 20BK/DG Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 3305 Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 3306 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 3307 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 3308 Oxygen Sensor: Locations Sensor - Oxygen 1/2 Component ID: 305 Component : SENSOR-OXYGEN 1/2 Connector: Name : SENSOR-OXYGEN 1/2 Color : BLACK # of pins : 4 Qualifier : (GAS) Pin Description Circuit 1 GROUND Z924 18BK/LB 2 O2 1/2 HEATER CONTROL K299 20BR/RD 3 O2 1/2 RETURN K904 20DB/DG 4 O2 1/2 SIGNAL K141 20DB/YL Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 3309 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 3310 Oxygen Sensor: Locations 1/1 Upstream - 2.0/2.4L The upstream oxygen sensor threads into the outlet flange of the exhaust manifold. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 3311 Oxygen Sensor: Locations 1/2 Downstream - 2.0/2.4L The downstream heated oxygen sensor threads into the catalytic converter. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Sensor-Oxygen 1/1 Oxygen Sensor: Diagrams Sensor-Oxygen 1/1 Component ID: 304 Component : SENSOR-OXYGEN 1/1 Connector: Name : SENSOR-OXYGEN 1/1 Color : GRAY # of pins : 4 Qualifier : (GAS) Pin Description Circuit 1 GROUND Z916 18BK 2 O2 1/1 HEATER CONTROL K99 20BR/OR 3 O2 1/1 RETURN K902 20BR/DG 4 O2 1/1 SIGNAL K41 20BK/DG Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Sensor-Oxygen 1/1 > Page 3314 Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Sensor-Oxygen 1/1 > Page 3315 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Sensor-Oxygen 1/1 > Page 3316 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Sensor-Oxygen 1/1 > Page 3317 Oxygen Sensor: Diagrams Sensor-Oxygen 1/2 Component ID: 305 Component : SENSOR-OXYGEN 1/2 Connector: Name : SENSOR-OXYGEN 1/2 Color : BLACK # of pins : 4 Qualifier : (GAS) Pin Description Circuit 1 GROUND Z924 18BK/LB 2 O2 1/2 HEATER CONTROL K299 20BR/RD 3 O2 1/2 RETURN K904 20DB/DG 4 O2 1/2 SIGNAL K141 20DB/YL Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Sensor-Oxygen 1/1 > Page 3318 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3319 Oxygen Sensor: Application and ID - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description Oxygen Sensor: Description and Operation Description DESCRIPTION The upstream oxygen sensor threads into the outlet flange of the exhaust manifold. The downstream heated oxygen sensor threads into the system depending on emission package. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description > Page 3322 Oxygen Sensor: Description and Operation Operation OPERATION Separate upstream and downstream grounds are used on the NGC vehicles (4 Cyl.). As vehicles accumulate mileage, the catalytic convertor deteriorates. The deterioration results in a less efficient catalyst. To monitor catalytic convertor deterioration, the fuel injection system uses two heated oxygen sensors. One sensor upstream of the catalytic convertor, one downstream of the convertor. The PCM compares the reading from the sensors to calculate the catalytic convertor oxygen storage capacity and converter efficiency. Also, the PCM uses the upstream heated oxygen sensor input when adjusting injector pulse width. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the malfunction indicator lamp (MIL). The O2 sensors produce a constant 2.5 volts on NGC vehicles, depending upon the oxygen content of the exhaust gas. When a large amount of oxygen is present (caused by a lean air/fuel mixture, can be caused by misfire and exhaust leaks), the sensors produce a low voltage. When there is a lesser amount of oxygen present (caused by a rich air/fuel mixture, which can be caused by internal engine problems) it produces a higher voltage. By monitoring the oxygen content and converting it to electrical voltage, the sensors act as a rich-lean switch. The oxygen sensors are equipped with a heating element that keeps the sensors at proper operating temperature during all operating modes. Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop operation the PCM monitors the O2 sensor's input (along with other inputs) and adjusts the injector pulse width accordingly. During Open Loop operation the PCM ignores the O2 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. The NGC Controller has a common ground for the heater in the O2S. 12 volts is supplied to the heater in the O2S by the NGC controller. Both the upstream and downstream O2 sensors for NGC are pulse width modulation (PWM). NOTE: When replacing an O2 Sensor, the PCM RAM memory must be cleared, either by disconnecting the PCM C-1 connector or momentarily disconnecting the Battery negative terminal. The NGC learns the characteristics of each O2 heater element and these old values should be cleared when installing a new O2 sensor. The customer may experience driveability issues if this is not performed. UPSTREAM OXYGEN SENSOR The input from the upstream heated oxygen sensor tells the PCM the oxygen content of the exhaust gas. Based on this input, the PCM fine tunes the air-fuel ratio by adjusting injector pulse width. The sensor input switches from 2.5 to 3.5 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air-fuel mixture), the sensor produces voltage as low as 2.5 volt. When there is a lesser amount of oxygen present (rich air-fuel mixture) the sensor produces a voltage as high as 3.5 volt. By monitoring the oxygen content and converting it to electrical voltage, the sensor acts as a rich-lean switch. The heating element in the sensor provides heat to the sensor ceramic element. Heating the sensor allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop, the PCM adjusts injector pulse width based on the upstream heated oxygen sensor input along with other inputs. In Open Loop, the PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. DOWNSTREAM OXYGEN SENSOR The downstream heated oxygen sensor input is used to detect catalytic convertor deterioration. As the convertor deteriorates, the input from the downstream sensor begins to match the upstream sensor input except for a slight time delay. By comparing the downstream heated oxygen sensor input to the input from the upstream sensor, the PCM calculates catalytic convertor efficiency. This is also used to establish the upstream O2 goal voltage (switching point). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal Oxygen Sensor: Service and Repair Removal 1/1 Upstream - 2.0/2.4L 1/1 UPSTREAM - 2.0/2.4L 1. Remove the engine cover. 2. Remove the negative battery cable. 3. Disconnect electrical connector from O2 sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 3325 4. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent. 1/2 Downstream - 2.0/2.4L 1/2 DOWNSTREAM - 2.0/2.4L Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 3326 The downstream heated oxygen sensor threads into the catalytic converter. 1. Remove the negative battery cable. 2. Raise vehicle and support. 3. Disconnect electrical connector from sensor. 4. Disconnect sensor electrical harness from clips along body. 5. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 3327 Oxygen Sensor: Service and Repair Installation 1/1 Upstream - 2.0/2.4L 1/1 UPSTREAM - 2.0/2.4L 1. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite(R) 771-64 or equivalent. New sensors have compound on the threads and do not require an additional coating. Tighten the sensor to 41 Nm (30 ft. lbs.). 2. Install sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 3328 3. Connect electrical connector to sensor. 4. Install the negative battery cable. 5. Install the engine cover. 1/2 Downstream - 2.0/2.4L 1/2 DOWNSTREAM - 2.0/2.4L Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 3329 The downstream heated oxygen sensor threads into the exhaust pipe behind the catalytic converter. 1. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite(R) 771-64 or equivalent. New sensors have compound on the threads and do not require an additional coating. Tighten the sensor to 41 Nm (30 ft. lbs.). 2. Install sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent. 3. Connect sensor electrical harness to clips along body. 4. Connect electrical connector to sensor. 5. Lower vehicle. 6. Install the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Page 3330 Oxygen Sensor: Tools and Equipment FUEL O2S (Oxygen Sensor) Remover/Installer-C-4907 O2S (Oxygen Sensor) Remover/Installer - 8439 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor Engine Control Module: Technical Service Bulletins Engine Controls - MIL On/DTC P0116/ECT Sensor NUMBER: 18-039-06 GROUP: Vehicle Performance DATE: December 6, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES FOR StarSCAN. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 7.02 SP2 OR HIGHER FOR THIS BULLETIN. SUBJECT: Flash: MIL Illumination DTC P0116 - Engine Coolant Temperature Sensor Performance OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) and the Transmission Control Module (1CM) with new software. CAUTION: VEHICLES EQUIPPED WITH A CVT TRANSMISSION MUST HAVE THE TRANSMISSION CONTROL MODULE (TCM) CHECKED FOR THE LATEST SOFTWARE LEVEL WHENEVER THE PCM SOFTWARE IS UPGRADED. IF NEWER TCM SOFTWARE IS AVAILABLE, IT MUST BE INSTALLED. MODELS: 2007 (PM) Caliber 2007 (MK49) Compass NOTE: This bulletin applies to PM/MK models equipped with a 1.8L, 2.0L or 2.4L gasoline engine (Sales Code EBA, ECN or ED3) and block heater (Sales Code NHK) built before November 20, 2006 (MDH 1120XX). NOTE: If an aftermarket or MOPAR accessory block heater is installed, the same conditions may apply. SYMPTOM/CONDITION: Some customers may experience MIL illumination after using the block heater. No other symptoms will be experienced. The technician may find the following DTC's: ^ P0116 - ENGINE COOLANT TEMPERATURE SENSOR PERFORMANCE DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If MIL illumination with DTC P0116 is present, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 3336 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING **STEP 5n and/or 8h**. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 7.02 SP2 software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. PM/MK Models equipped with a CVT must have the TCM reprogrammed as follows: 6. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. 7. Is the TCM part number recorded in step 6e above, the same as the new p/n shown on the "Flash File List" screen? a. Yes >> No further action is necessary. Proceed to Step 9. b. No >> the TCM will require flash reprogramming, proceed to Step 8. 8. Flash reprogram the TCM as follows: a. From the "Flash File List" screen, select "Download to Scantool". b. Select "Close" after the download is complete, then select "Back". c. Highlight the listed calibration. d. Select "Update Controller". Follow on screen instructions. e. When the update is complete, select "OK". f. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. g. Turn the ignition switch to the OFF position for no less than 15 seconds. h. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 3337 CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the TCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. ** NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 9. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 3338 Engine Control Module: Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 3339 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 3340 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 3341 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3342 Engine Control Module: Locations Component ID: 160 Component : MODULE-POWERTRAIN CONTROL Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK # of pins : 58 Qualifier : (GAS) Pin Description Circuit 1 FUSED MAIN RELAY OUTPUT F342 14BR/DG 2 GROUND Z925 16BK/YL 3 FUSED MAIN RELAY OUTPUT F342 14BR/DG 4 GROUND Z925 16BK/YL 5-6-- 7 O2 1/2 HEATER CONTROL K299 20BR/RD 8-9-10 - 11 - 12 - 13 S/C SWITCH GROUND V937 20VT/BR 14 - 15 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 16 FUSED B(+) A931 20RD/WT 17 - 18 - 19 FUEL PUMP CONTROL K31 20BR 20 O2 1/2 RETURN K904 20DB/DG 21 O2 1/2 SIGNAL K141 20DB/YL 22 5 VOLT SUPPLY K858 20BR/GY 23 5 VOLT SUPPLY F856 20YL/PK 24 - 25 STARTER CONTROL T752 20DG/OR 26 S/C SIGNAL 2 V72 20OR/VT 27 S/C SIGNAL 1 V71 20VT/OR 28 - 29 - 30 SENSOR GROUND K914 20DB/PK 31 - 32 BRAKE SIGNAL 1 B15 20DG/WT 33 - 34 APP SENSOR GROUND 2 K400 20BR/VT Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3343 35 EVAP PURGE RETURN K70 20DB/BR 36 APP SENSOR GROUND 1 K167 20BR/YL 37 START ENABLE F963 20PK/DB 38 VEHICLE SPEED SIGNAL K75 20DB/OR 39 EVAP PURGE CONTROL K52 20DB/WT 40 - 41 CAN C BUS (+) D65 20WT/BK 42 - 43 - 44 - 45 - - 46 - 47 ESM SIGNAL K107 20VT/WT 48 APP SIGNAL 2 K29 20WT/BR 49 APP SIGNAL 1 K23 20BR/OR 50 CLUTCH INTERLOCK SIGNAL T141 20YL/RD 51 - 52 BRAKE SIGNAL 2 B16 20LB/DG 53 GEN SENSE A804 20RD/GY 54 CAN C BUS (-) D64 20WT/LB 55 - 56 - 57 - 58 MAIN RELAY CONTROL K51 20BR/LG Component Location - 8 Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3344 Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3345 Connector: Name : MODULE-POWERTRAIN CONTROL C2 Color : BLACK # of pins : 96 Qualifier : (GAS) Pin Description Circuit 1 ETC MOTOR (+) K124 20DB/GY 2-3-4-- Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3346 5-- 6 A/C COMPRESSOR CONTROL C27 20LB/WT 7-8 IAT SIGNAL K21 20BK/RD 9-10 - 11 ECT 2 SIGNAL K222 20BR/YL 12 - 13 - 14 - 15 - 16 - 17 - 18 - 19 - 20 - 21 INJECTOR 3 CONTROL K13 20BR/LB 22 INJECTOR 4 CONTROL K14 20BR/TN 23 INJECTOR 1 CONTROL K11 20YL/BR 24 INJECTOR 2 CONTROL K12 20BR/DB 25 ETC MOTOR (-) K126 20DB/LG 26 - 27 MFV CONTROL K601 20BR/VT 28 - 29 - 30 - 31 - 32 - 33 O2 1/1 SIGNAL K41 20BK/DG 34 - 35 - 36 O2 1/1 RETURN K902 20BR/DG 37 EOT SIGNAL G24 20VT/BR 38 CMP 1/2 SIGNAL K441 20DB/BR 39 - 40 - 41 5 VOLT SUPPLY F855 20PK/YL 42 5 VOLT SUPPLY K857 20BR/LG 43 - 44 - 45 - 46 - 47 - 48 - 49 O2 1/1 HEATER CONTROL K99 20BR/OR 50 - 51 GEN FIELD CONTROL K20 20BR/GY 52 - 53 - 54 - 55 - 56 - 57 CMP 1/1 SIGNAL K44 20DB 58 SENSOR GROUND K915 20BR/WT 59 - 60 - 61 - 62 TP SENSOR GROUND K922 20BR 63 TP SIGNAL 2 K122 20DG/BR 64 TP SIGNAL 1 K22 20OR/BR 65 KS RETURN K942 20WT/BR 66 - 67 - - 68 - 69 - 70 CMP 1/1 CONTROL K76 20LB/WT Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3347 71 - 72 CMP 1/2 CONTROL K276 20DB/WT 73 COIL 4 CONTROL K15 18GY/DB 74 COIL 3 CONTROL K18 18DB/OR 75 COIL 2 CONTROL K17 18DB/TN 76 COIL 1 CONTROL K19 18DG/LB 77 - 78 - 79 CKP SIGNAL K24 20LB/BR 80 - 81 - - 82 SENSOR GROUND K900 20DB/DG 83 ECT 1 SIGNAL K2 20VT/OR 84 MFV SIGNAL K602 20YL/DB 85 MAP SIGNAL K1 20VT/LB 86 EOP SIGNAL G6 20VT/GY 87 - 88 KS SIGNAL K42 20LG/DB 89 - 90 - 91 - 92 - 93 - 94 - 95 - 96 - Component Location - 8 Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3348 Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3349 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: Provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3352 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3353 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3354 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3355 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3356 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3357 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3358 5. Release the Secondary Terminal Lock, if required (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3359 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3360 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3361 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3362 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3363 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3364 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3365 Engine Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3366 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3367 STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3368 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3369 Engine Control Module: Connector Views Component ID: 160 Component : MODULE-POWERTRAIN CONTROL Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK # of pins : 58 Qualifier : (GAS) Pin Description Circuit 1 FUSED MAIN RELAY OUTPUT F342 14BR/DG 2 GROUND Z925 16BK/YL 3 FUSED MAIN RELAY OUTPUT F342 14BR/DG 4 GROUND Z925 16BK/YL 5-6-- 7 O2 1/2 HEATER CONTROL K299 20BR/RD 8-9-10 - 11 - 12 - 13 S/C SWITCH GROUND V937 20VT/BR 14 - 15 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 16 FUSED B(+) A931 20RD/WT 17 - 18 - 19 FUEL PUMP CONTROL K31 20BR 20 O2 1/2 RETURN K904 20DB/DG 21 O2 1/2 SIGNAL K141 20DB/YL 22 5 VOLT SUPPLY K858 20BR/GY 23 5 VOLT SUPPLY F856 20YL/PK 24 - 25 STARTER CONTROL T752 20DG/OR 26 S/C SIGNAL 2 V72 20OR/VT 27 S/C SIGNAL 1 V71 20VT/OR 28 - 29 - 30 SENSOR GROUND K914 20DB/PK 31 - 32 BRAKE SIGNAL 1 B15 20DG/WT 33 - 34 APP SENSOR GROUND 2 K400 20BR/VT Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3370 35 EVAP PURGE RETURN K70 20DB/BR 36 APP SENSOR GROUND 1 K167 20BR/YL 37 START ENABLE F963 20PK/DB 38 VEHICLE SPEED SIGNAL K75 20DB/OR 39 EVAP PURGE CONTROL K52 20DB/WT 40 - 41 CAN C BUS (+) D65 20WT/BK 42 - 43 - 44 - 45 - - 46 - 47 ESM SIGNAL K107 20VT/WT 48 APP SIGNAL 2 K29 20WT/BR 49 APP SIGNAL 1 K23 20BR/OR 50 CLUTCH INTERLOCK SIGNAL T141 20YL/RD 51 - 52 BRAKE SIGNAL 2 B16 20LB/DG 53 GEN SENSE A804 20RD/GY 54 CAN C BUS (-) D64 20WT/LB 55 - 56 - 57 - 58 MAIN RELAY CONTROL K51 20BR/LG Component Location - 8 Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3371 Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3372 Connector: Name : MODULE-POWERTRAIN CONTROL C2 Color : BLACK # of pins : 96 Qualifier : (GAS) Pin Description Circuit 1 ETC MOTOR (+) K124 20DB/GY 2-3-4-- Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3373 5-- 6 A/C COMPRESSOR CONTROL C27 20LB/WT 7-8 IAT SIGNAL K21 20BK/RD 9-10 - 11 ECT 2 SIGNAL K222 20BR/YL 12 - 13 - 14 - 15 - 16 - 17 - 18 - 19 - 20 - 21 INJECTOR 3 CONTROL K13 20BR/LB 22 INJECTOR 4 CONTROL K14 20BR/TN 23 INJECTOR 1 CONTROL K11 20YL/BR 24 INJECTOR 2 CONTROL K12 20BR/DB 25 ETC MOTOR (-) K126 20DB/LG 26 - 27 MFV CONTROL K601 20BR/VT 28 - 29 - 30 - 31 - 32 - 33 O2 1/1 SIGNAL K41 20BK/DG 34 - 35 - 36 O2 1/1 RETURN K902 20BR/DG 37 EOT SIGNAL G24 20VT/BR 38 CMP 1/2 SIGNAL K441 20DB/BR 39 - 40 - 41 5 VOLT SUPPLY F855 20PK/YL 42 5 VOLT SUPPLY K857 20BR/LG 43 - 44 - 45 - 46 - 47 - 48 - 49 O2 1/1 HEATER CONTROL K99 20BR/OR 50 - 51 GEN FIELD CONTROL K20 20BR/GY 52 - 53 - 54 - 55 - 56 - 57 CMP 1/1 SIGNAL K44 20DB 58 SENSOR GROUND K915 20BR/WT 59 - 60 - 61 - 62 TP SENSOR GROUND K922 20BR 63 TP SIGNAL 2 K122 20DG/BR 64 TP SIGNAL 1 K22 20OR/BR 65 KS RETURN K942 20WT/BR 66 - 67 - - 68 - 69 - 70 CMP 1/1 CONTROL K76 20LB/WT Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3374 71 - 72 CMP 1/2 CONTROL K276 20DB/WT 73 COIL 4 CONTROL K15 18GY/DB 74 COIL 3 CONTROL K18 18DB/OR 75 COIL 2 CONTROL K17 18DB/TN 76 COIL 1 CONTROL K19 18DG/LB 77 - 78 - 79 CKP SIGNAL K24 20LB/BR 80 - 81 - - 82 SENSOR GROUND K900 20DB/DG 83 ECT 1 SIGNAL K2 20VT/OR 84 MFV SIGNAL K602 20YL/DB 85 MAP SIGNAL K1 20VT/LB 86 EOP SIGNAL G6 20VT/GY 87 - 88 KS SIGNAL K42 20LG/DB 89 - 90 - 91 - 92 - 93 - 94 - 95 - 96 - Component Location - 8 Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3375 Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3376 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description Engine Control Module: Description and Operation Description PCM Ground PCM GROUND Ground is provided through multiple pins of the PCM connector. Depending on the vehicle there may be as many as two different ground pins. There are power grounds and sensor grounds. The power grounds are used to control the ground side relays, solenoids, ignition coil or injectors. The signal ground is used for any input that uses sensor return for ground, and the ground side of any internal processing component. The PCM case is shielded to prevent RFI and EMI. The PCM case is grounded and must be firmly attached to a good, clean body ground. Internally all grounds are connected together, however there is noise suppression on the sensor ground. For EMI and RFI protection the housing and cover are also grounded separately from the ground pins. Sensor Return - PCM Input SENSOR RETURN - PCM INPUT The sensor return circuit provides a low electrical noise ground reference for all of the systems sensors. The sensor return circuit connects to internal ground circuits within the Powertrain Control Module (PCM). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description > Page 3379 Engine Control Module: Description and Operation Operation Powertrain Control Module POWERTRAIN CONTROL MODULE The PCM receives input signals from various switches and sensors that are referred to as PCM Inputs. Based on these inputs, the PCM adjusts various engine and vehicle operations through devices that are referred to as PCM Outputs. NOTE: PCM Inputs: - Air Conditioning Controls - Battery Voltage - Brake Switch - Camshaft Position Sensor - Clutch Upstop Switch - Clutch Interlock - Crankshaft Position Sensor - Engine Coolant Temperature Sensor - Fuel Level Sensor (Bus message) - Ignition Switch - Intake Air Temperature Sensor - Knock Sensor - Evaporative System Integrity Monitor - Manifold Absolute Pressure (MAP) Sensor - Oil Pressure Switch - Oxygen Sensors - Power Steering Pressure Switch - Speed Control Switches - Vehicle Speed Sensor (MTX-equipped models) NOTE: PCM Outputs: - Air Conditioning Clutch Relay - Charging Indicator Lamp (Bus Message) - Proportional Purge Solenoid - Fuel Injectors - Generator Field - Ignition Coils - Malfunction Indicator (Check Engine) Lamp (Bus Message) - Manifold Flow Valve - Oxygen Sensors Heater Controls - Variable Valve Timing - Vehicle Speed (Manual Transmission) Based on inputs it receives, the PCM adjusts fuel injector pulse width, idle speed, ignition spark advance, ignition coil dwell and EVAP canister purge operation. The PCM also determines the appropriate transmission shift schedule and shift points, depending on the present operating conditions and driver demand. The PCM regulates the cooling fan, air conditioning and speed control systems. The PCM changes generator charge rate by adjusting the Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description > Page 3380 generator field. The PCM also performs diagnostics. The PCM adjusts injector pulse width (air-fuel ratio) based on the following inputs. - Battery voltage - Coolant temperature - Exhaust gas content (oxygen sensor) - Engine speed (crankshaft position sensor) - Intake air temperature - Manifold absolute pressure - Throttle position The PCM adjusts ignition timing based on the following inputs. - Coolant temperature - Engine speed (crankshaft position sensor) - Knock sensor - Manifold absolute pressure - Throttle position - Transmission gear selection (park/neutral switch) - Intake air temperature The PCM also adjusts engine idle speed through the idle air control motor based on the following inputs. - Air conditioning sense - Battery voltage - Brake switch - Coolant temperature - Engine speed (crankshaft position sensor) - Engine run time - Manifold absolute pressure - Power steering pressure switch - Throttle position - Transmission gear selection (park/neutral switch) - Vehicle distance (speed) The camshaft position sensor and crankshaft position sensor signals are sent to the PCM. If the PCM does not receive the signal within approximately 1 second of engine cranking, it deactivates the fuel pump. When these are deactivated, power is shut off to the fuel injectors, ignition coils, oxygen sensor heating elements and fuel pump. The PCM contains a voltage converter that changes battery voltage to a regulated 5 volt direct current to power the camshaft position sensor, crankshaft position sensor, manifold absolute pressure sensor, throttle position sensor, A/C pressure switch, A/C pressure transducer, and vehicle speed sensor. 5 Volt Supply - PCM Output 5 VOLT SUPPLY - PCM OUTPUT The PCM supplies 5 volts to the following sensors: - A/C pressure transducer - Ambient Temperature sensor - Battery temperature - Camshaft Position Sensor (NGC) - Crankshaft Position Sensor (NGC) - Engine coolant temperature sensor - Inlet Air Temperature Sensor - Knock sensor - Linear EGR solenoid (if equipped) - Manifold absolute pressure sensor - Oil Pressure Switch Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM/SKREEM Programming Engine Control Module: Testing and Inspection PCM/ECM/SKREEM Programming PCM/ECM/SKREEM PROGRAMMING NOTE: Before replacing the Powertrain Control Module (PCM) or Engine Control Module (ECM), be certain to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most PCM/ECM driver/control circuit failures are caused by internal component failures (i.e. relays and solenoids) and shorted circuits (i.e. pull-ups, drivers, and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has been set. When a PCM, or ECM, and the Sentry Key REmote Entry Module (SKREEM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: 1. Program the new PCM or ECM. 2. Program the new SKREEM (also sometimes referred to as the Wireless Control Module or WCM). 3. Replace all ignition keys and program them into the new SKREEM/WCM. PROGRAMMING THE SKREEM The SKIS Secret Key is an ID code that is unique to each SKREEM/WCM. This code is programmed and stored in the SKREEM/WCM, the PCM/ECM, and each ignition key transponder chip. When the PCM or SKREEM/WCM is replaced, it is necessary to program the Secret Key into the new module using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool for "PCM Replaced" or "WCM Replaced" under "Miscellaneous Functions" for the "WCM/Wireless Control Module" menu item as appropriate. NOTE: If the PCM/ECM and the SKREEM/WCM are replaced at the same time, all vehicle ignition keys will need to be replaced and new keys programmed into the new SKREEM/WCM. NOTE: Programming the PCM/ECM or SKREEM is done using a diagnostic scan tool and a PIN to enter secure access mode. If eight attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. (Ensure all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary). PROGRAMMING IGNITION KEYS TO THE SKREEM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKREEM/WCM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKREEM/WCM. To program ignition keys into the SKREEM/WCM, follow the programming steps outlined in the diagnostic scan tool for PROGRAM IGNITION KEYS OR KEY FOBS under MISCELLANEOUS FUNCTIONS for the WCM/WIRELESS CONTROL MODULE menu item. NOTE: A maximum of eight keys can be learned to each SKREEM. Once a key is learned to a SKREEM, that key has acquired the Secret Key for that SKREEM and cannot be transferred to any other SKREEM or vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: - Programming Not Attempted - The scan tool attempts to read the programmed key status and there are no keys programmed into SKREEM memory. - Programming Key Failed (Possible Used Key From Wrong Vehicle) - SKREEM is unable to program an ignition key transponder due to one of the following: - The ignition key transponder is faulty. - The ignition key transponder is or has been already programmed to another vehicle. - 8 Keys Already Learned, Programming Not Done - The SKREEM transponder ID memory is full. - Learned Key In Ignition - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKREEM memory. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM/SKREEM Programming > Page 3383 Engine Control Module: Testing and Inspection Pinion Factor Setting PINION FACTOR SETTING NOTE: This procedure must be performed if the PCM has been replaced with a NEW or replacement unit. Failure to perform this procedure will result in an inoperative or improperly calibrated speedometer. The vehicle speed readings for the speedometer are taken from the output speed sensor. The PCM must be calibrated to the different combinations of equipment (final drive and tires) available. Pinion Factor allows the technician to set the Powertrain Control Module initial setting so that the speedometer readings will be correct. To properly read and/or reset the Pinion Factor, it is necessary to use a scan tool. 1. Plug the scan tool into the diagnostic connector located under the instrument panel. 2. Select the Transmission menu. 3. Select the Miscellaneous menu. 4. Select Pinion Factor. Then follow the instructions on the scan tool screen. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal Engine Control Module: Service and Repair Removal REMOVAL USE THE SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM) WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (VIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. To avoid possible voltage spike damage to PCM, ignition key must be off, and negative battery cable must be disconnected before unplugging PCM connectors. 1. Disconnect negative battery cable. 2. Unlock and disconnect the electrical connectors from PCM. 3. Remove the air cleaner box. 4. Remove the three mounting bolts. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal > Page 3386 5. Tip module out and remove from bracket. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal > Page 3387 Engine Control Module: Service and Repair Installation INSTALLATION USE THE SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM) WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (VIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. 1. Tip module into bracket. 2. Install three mounting bolts and tighten to 9 Nm (80 in. lbs.) torque. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal > Page 3388 3. Check pins in electrical connectors for damage. Repair as necessary. 4. Connect electrical connectors and lock. 5. Install air cleaner box. 6. Connect negative battery cable. 7. Use the scan tool to reprogram new PCM with vehicles original Identification Number (VIN) and original vehicle mileage. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Main Relay is located in the Fuse/Relay block. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3392 Main Relay (Computer/Fuel System): Diagrams Component ID: 182 Component : RELAY-MAIN Connector: Name : RELAY-MAIN Color : # of pins : 0 B6 FUSED B(+) A14 12RD/YL B7 MAIN RELAY OUTPUT K542 12BR/WT B8 - B9 FUSED B(+) A14 12RD/YL B10 MAIN RELAY CONTROL K51 20BR/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Component ID: 281 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 APP SIGNAL 2 K29 20WT/BR 2 APP SENSOR GROUND 2 K400 20BR/VT 3 5 VOLT SUPPLY K854 20VT/BR 3 5 VOLT SUPPLY K858 20BR/GY 4 APP SIGNAL 1 K23 20BR/OR 5 APP SENSOR GROUND 1 K167 20BR/YL 6 5 VOLT SUPPLY K852 20BR/VT 6 5 VOLT SUPPLY F856 20YL/PK Component Location - 44 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3397 Component Location - 47 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3398 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3399 Accelerator Pedal Position Sensor: Diagrams Component ID: 281 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 APP SIGNAL 2 K29 20WT/BR 2 APP SENSOR GROUND 2 K400 20BR/VT 3 5 VOLT SUPPLY K854 20VT/BR 3 5 VOLT SUPPLY K858 20BR/GY 4 APP SIGNAL 1 K23 20BR/OR 5 APP SENSOR GROUND 1 K167 20BR/YL 6 5 VOLT SUPPLY K852 20BR/VT 6 5 VOLT SUPPLY F856 20YL/PK Component Location - 44 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3400 Component Location - 47 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3401 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3402 Accelerator Pedal Position Sensor: Description and Operation DESCRIPTION The Accelerator Pedal Position Sensor (APPS) is a variable resistor that provides the PCM with an input signal (voltage). The signal represents pedal angle position. As the position of the accelerator pedal changes, the resistance of the APPS changes. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal Accelerator Pedal Position Sensor: Service and Repair Removal REMOVAL 1. Disconnect negative battery cable. 2. Disconnect the electrical connector from the module. 3. Remove the mounting nuts. 4. Remove assembly from the mounting studs. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal > Page 3405 Accelerator Pedal Position Sensor: Service and Repair Installation INSTALLATION 1. Install APPS module. 2. Tighten the mounting nuts. 3. Connect electrical connector. 4. Connect negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Sensor-Camshaft 1/1 Position Camshaft Position Sensor: Locations Sensor-Camshaft 1/1 Position Component ID: 284 Component : SENSOR-CAMSHAFT 1/1 POSITION Connector: Name : SENSOR-CAMSHAFT 1/1 POSITION Color : BLACK # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY K857 20BR/LG 2 SENSOR GROUND K900 20DB/DG 3 CMP 1/1 SIGNAL K44 20DB Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Sensor-Camshaft 1/1 Position > Page 3410 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Sensor-Camshaft 1/1 Position > Page 3411 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Sensor-Camshaft 1/1 Position > Page 3412 Camshaft Position Sensor: Locations Sensor-Camshaft 1/2 Position Component ID: 285 Component : SENSOR-CAMSHAFT 1/2 POSITION Connector: Name : SENSOR-CAMSHAFT 1/2 POSITION Color : BLACK # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K915 20BR/WT 3 CMP 1/2 SIGNAL K441 20DB/BR Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Sensor-Camshaft 1/1 Position > Page 3413 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Sensor-Camshaft 1/1 Position Camshaft Position Sensor: Diagrams Sensor-Camshaft 1/1 Position Component ID: 284 Component : SENSOR-CAMSHAFT 1/1 POSITION Connector: Name : SENSOR-CAMSHAFT 1/1 POSITION Color : BLACK # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY K857 20BR/LG 2 SENSOR GROUND K900 20DB/DG 3 CMP 1/1 SIGNAL K44 20DB Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Sensor-Camshaft 1/1 Position > Page 3416 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Sensor-Camshaft 1/1 Position > Page 3417 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Sensor-Camshaft 1/1 Position > Page 3418 Camshaft Position Sensor: Diagrams Sensor-Camshaft 1/2 Position Component ID: 285 Component : SENSOR-CAMSHAFT 1/2 POSITION Connector: Name : SENSOR-CAMSHAFT 1/2 POSITION Color : BLACK # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K915 20BR/WT 3 CMP 1/2 SIGNAL K441 20DB/BR Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Sensor-Camshaft 1/1 Position > Page 3419 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Description Camshaft Position Sensor: Description and Operation Description DESCRIPTION The camshaft position sensors are mounted to the front and rear of the cylinder head. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Description > Page 3422 Camshaft Position Sensor: Description and Operation Operation OPERATION The PCM sends approximately 5 volts to the Hall-effect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. The input to the PCM occurs on a 5 volt output reference circuit. A ground for the sensor is provided through the sensor return circuit. The PCM identifies camshaft position by registering the change from 5 to 0 volts, as signaled from the camshaft position sensor. The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Removal Camshaft Position Sensor: Service and Repair Removal Front Camshaft Position Sensor FRONT CAMSHAFT POSITION SENSOR 1. Remove the air cleaner hose to throttle body, disconnect the inlet air temperature sensor electrical connector. 2. Disconnect negative battery cable. 3. Disconnect electrical connector from camshaft position sensor. 4. Remove camshaft position sensor mounting screws. 5. Remove sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 3425 Rear Camshaft Position Sensor REAR CAMSHAFT POSITION SENSOR 1. Disconnect negative battery cable. 2. Disconnect electrical connector at sensor. 3. Remove nut retaining heat shield. 4. Pull heat shield out to uncover sensor. 5. Remove mounting bolt. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 3426 6. Remove sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 3427 Camshaft Position Sensor: Service and Repair Installation Front Camshaft Position Sensor FRONT CAMSHAFT POSITION SENSOR 1. Lubricate sensor O-ring. 2. Install camshaft position sensor utilizing twisting motion. Make sure sensor is fully seated. Do not drive sensor into the bore with screw. This can cause sensor to be incorrectly seated causing engine to fail. Tighten sensor mounting screws to 9 Nm (79.5 in. lbs.). 3. Carefully attach electrical connector to camshaft position sensor. Installation at an angle may damage the sensor pins. 4. Install the negative battery cable. 5. Install the air cleaner to throttle body hose, connect the inlet air temperature sensor electrical connector. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 3428 Rear Camshaft Position Sensor REAR CAMSHAFT POSITION SENSOR 1. Lubricate sensor O-ring. 2. Install sensor utilizing twisting motion. Make sure sensor is fully seated. Do not drive sensor into the bore with screw. This can cause sensor to be incorrectly seated causing engine to fail. 3. Install mounting bolt and tighten to 9 Nm (79.5 in. lbs.). 4. Carefully attach electrical connector to camshaft position sensor. Fill for positive lock (click). Installation at angle may damage the sensor pins. 5. Install heat shield onto mounting stud. 6. Install heat shield retaining nut and tighten. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 3429 7. Connect the electrical connector. 8. Connect negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor Coolant Temperature Sensor/Switch (For Computer): Technical Service Bulletins Engine Controls MIL On/DTC P0116/ECT Sensor NUMBER: 18-039-06 GROUP: Vehicle Performance DATE: December 6, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES FOR StarSCAN. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 7.02 SP2 OR HIGHER FOR THIS BULLETIN. SUBJECT: Flash: MIL Illumination DTC P0116 - Engine Coolant Temperature Sensor Performance OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) and the Transmission Control Module (1CM) with new software. CAUTION: VEHICLES EQUIPPED WITH A CVT TRANSMISSION MUST HAVE THE TRANSMISSION CONTROL MODULE (TCM) CHECKED FOR THE LATEST SOFTWARE LEVEL WHENEVER THE PCM SOFTWARE IS UPGRADED. IF NEWER TCM SOFTWARE IS AVAILABLE, IT MUST BE INSTALLED. MODELS: 2007 (PM) Caliber 2007 (MK49) Compass NOTE: This bulletin applies to PM/MK models equipped with a 1.8L, 2.0L or 2.4L gasoline engine (Sales Code EBA, ECN or ED3) and block heater (Sales Code NHK) built before November 20, 2006 (MDH 1120XX). NOTE: If an aftermarket or MOPAR accessory block heater is installed, the same conditions may apply. SYMPTOM/CONDITION: Some customers may experience MIL illumination after using the block heater. No other symptoms will be experienced. The technician may find the following DTC's: ^ P0116 - ENGINE COOLANT TEMPERATURE SENSOR PERFORMANCE DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If MIL illumination with DTC P0116 is present, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 3434 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING **STEP 5n and/or 8h**. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 7.02 SP2 software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. PM/MK Models equipped with a CVT must have the TCM reprogrammed as follows: 6. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. 7. Is the TCM part number recorded in step 6e above, the same as the new p/n shown on the "Flash File List" screen? a. Yes >> No further action is necessary. Proceed to Step 9. b. No >> the TCM will require flash reprogramming, proceed to Step 8. 8. Flash reprogram the TCM as follows: a. From the "Flash File List" screen, select "Download to Scantool". b. Select "Close" after the download is complete, then select "Back". c. Highlight the listed calibration. d. Select "Update Controller". Follow on screen instructions. e. When the update is complete, select "OK". f. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. g. Turn the ignition switch to the OFF position for no less than 15 seconds. h. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 3435 CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the TCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. ** NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 9. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Sensor-Engine Coolant Temperature 1 Coolant Temperature Sensor/Switch (For Computer): Locations Sensor-Engine Coolant Temperature 1 Component ID: 290 Component : SENSOR-ENGINE COOLANT TEMPERATURE 1 Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE 1 Color : DK. GRAY # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 SENSOR GROUND K900 20DB/DG 2 ECT 1 SIGNAL K2 20VT/OR Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Sensor-Engine Coolant Temperature 1 > Page 3438 Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Sensor-Engine Coolant Temperature 1 > Page 3439 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Sensor-Engine Coolant Temperature 1 > Page 3440 Coolant Temperature Sensor/Switch (For Computer): Locations Sensor-Engine Coolant Temperature 2 Component ID: 291 Component : SENSOR-ENGINE COOLANT TEMPERATURE 2 Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE 2 Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 SENSOR GROUND K915 20BR/WT 2 ECT 2 SIGNAL K222 20BR/YL Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Sensor-Engine Coolant Temperature 1 > Page 3441 Component Location - 15 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Sensor-Engine Coolant Temperature 1 > Page 3442 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Sensor-Engine Coolant Temperature 1 Coolant Temperature Sensor/Switch (For Computer): Diagrams Sensor-Engine Coolant Temperature 1 Component ID: 290 Component : SENSOR-ENGINE COOLANT TEMPERATURE 1 Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE 1 Color : DK. GRAY # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 SENSOR GROUND K900 20DB/DG 2 ECT 1 SIGNAL K2 20VT/OR Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Sensor-Engine Coolant Temperature 1 > Page 3445 Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Sensor-Engine Coolant Temperature 1 > Page 3446 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Sensor-Engine Coolant Temperature 1 > Page 3447 Coolant Temperature Sensor/Switch (For Computer): Diagrams Sensor-Engine Coolant Temperature 2 Component ID: 291 Component : SENSOR-ENGINE COOLANT TEMPERATURE 2 Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE 2 Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 SENSOR GROUND K915 20BR/WT 2 ECT 2 SIGNAL K222 20BR/YL Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Sensor-Engine Coolant Temperature 1 > Page 3448 Component Location - 15 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Sensor-Engine Coolant Temperature 1 > Page 3449 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Component ID: 287 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 CKP SENSOR 5 VOLT SUPPLY K853 20DB/BR 2 CKP SENSOR SIGNAL K24 20BR/LB 3 CKP SENSOR GROUND K925 20DB/WT Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3453 Component Location - 19 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3454 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3455 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20LB/BR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3456 Component Location - 16 Component Location - 19 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3457 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3458 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3459 Crankshaft Position Sensor: Diagrams Component ID: 287 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 CKP SENSOR 5 VOLT SUPPLY K853 20DB/BR 2 CKP SENSOR SIGNAL K24 20BR/LB 3 CKP SENSOR GROUND K925 20DB/WT Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3460 Component Location - 19 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3461 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3462 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20LB/BR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3463 Component Location - 16 Component Location - 19 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3464 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3465 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description DESCRIPTION The crankshaft position sensor mounts to the rear of the engine block near the transmission. The PCM uses the Crankshaft Position sensor to calculate the following: - Engine RPM - TDC number 1 and 4 - Ignition coil synchronization - Injector synchronization - Camshaft-to-crankshaft misalignment (Timing belt skipped 1 tooth or more diagnostic trouble code). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 3468 Crankshaft Position Sensor: Description and Operation Operation OPERATION The PCM sends approximately 5 volts to the Hall-effect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. A ground for the sensor is provided through the sensor return circuit. The input to the PCM occurs on a 5 volt output reference circuit that operates as follows: The Hall-effect sensor contains a powerful magnet. As the magnetic field passes over the dense portion of the counterweight, the 5-volt signal is pulled to ground (0.3 volts) through a transistor in the sensor. When the magnetic field passes over the notches in the crankshaft counterweight, the magnetic field turns off the transistor in the sensor, causing the PCM to register the 5-volt signal. The PCM identifies crankshaft position by registering the change from 5 to 0 volts, as signaled from the Crankshaft Position sensor (2). The PCM determines which cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. The #8 crankshaft counterweight has a target ring with 32 teeth and notches (1), including one long reference tooth and notch. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Removal Crankshaft Position Sensor: Service and Repair Removal 2.0/2.4L The Crankshaft Position Sensor is in the rear of the engine block near the transmission. If vehicle is All Wheel Drive the Power Transfer Unit must be removed. 1. Disconnect the negative battery cable. 2. Raise vehicle and support. 3. Remove heat shield retaining bolt. 4. Remove heat shield. 5. Unlock and disconnect the electrical connector to the crankshaft position sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Removal > Page 3471 6. Remove the crankshaft position sensor bolt. 7. Remove the sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Removal > Page 3472 Crankshaft Position Sensor: Service and Repair Installation 2.0/2.4L 1. Check O-ring for damage and lubricate the O-ring with engine oil before installing sensor. 2. Use a twisting motion when installing the sensor. 3. Install and tighten the crankshaft position sensor bolt and tighten to 9 Nm (79.5 in. lbs.). 4. Connect and lock the electrical connector to the crankshaft position sensor. 5. Install heat shield and retaining bolt. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Removal > Page 3473 If vehicle is All Wheel Drive the Power Transfer Unit must be installed. 6. Lower vehicle. 7. Connect the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations Component ID: 297 Component : SENSOR-INTAKE AIR TEMPERATURE Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 IAT SIGNAL K21 20BK/RD 2 SENSOR GROUND K915 20BR/WT Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3477 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3478 Intake Air Temperature Sensor: Diagrams Component ID: 297 Component : SENSOR-INTAKE AIR TEMPERATURE Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 IAT SIGNAL K21 20BK/RD 2 SENSOR GROUND K915 20BR/WT Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3479 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3480 Intake Air Temperature Sensor: Description and Operation DESCRIPTION The IAT Sensor is a Negative Temperature Coefficient (NTC) Sensor that provides information to the PCM regarding the temperature of the air entering the intake manifold. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Removal Intake Air Temperature Sensor: Service and Repair Removal 2.0/2.4L The sensor is located in the clean air duct. 1. Disconnect the negative battery cable. 2. Disconnect electrical connector from the sensor. 3. Remove the sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Removal > Page 3483 Intake Air Temperature Sensor: Service and Repair Installation 2.0/2.4L The sensor is in the clean air duct. 1. Install sensor. Make sure of sensor orientation. 2. Attach electrical connector to sensor. 3. Connect the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Component ID: 299 Component : SENSOR-KNOCK Connector: Name : SENSOR-KNOCK Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 KS SIGNAL K42 20LG/DB 2 KS RETURN K942 20WT/BR Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3487 Component Location - 15 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3488 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3489 Knock Sensor: Diagrams Component ID: 299 Component : SENSOR-KNOCK Connector: Name : SENSOR-KNOCK Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 KS SIGNAL K42 20LG/DB 2 KS RETURN K942 20WT/BR Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3490 Component Location - 15 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3491 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Description Knock Sensor: Description and Operation Description DESCRIPTION The knock sensor is bolted to the cylinder block. The knock sensor is designed to detect engine vibration that is caused by detonation or preignition. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Description > Page 3494 Knock Sensor: Description and Operation Operation OPERATION When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives as an input the knock sensor voltage signal. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, ignition timing retard is allowed. Ignition timing is retarded uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard ignition timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except WOT. The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening affects knock sensor performance, possibly causing improper spark control. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Removal Knock Sensor: Service and Repair Removal 2.0/2.4L The knock sensor bolts into the side of the cylinder block in front of the starter under the intake manifold. 1. Disconnect the negative battery cable. 2. Remove the bolt holding the knock sensor. 3. Remove sensor with electrical connector attached. 4. Disconnect electrical connector from knock sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Removal > Page 3497 5. Remove the knock sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Removal > Page 3498 Knock Sensor: Service and Repair Installation 2.0/2.4L The knock sensor bolts into the side of the cylinder block in front of the starter under the intake manifold. 1. Attach electrical connector to knock sensor. 2. Install knock sensor. Tighten knock sensor bolt to 22 Nm (195 in. lbs.). Over or under tightening effects knock sensor performance, possibly causing improper spark control. 3. Connect the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations Component ID: 300 Component : SENSOR-MAP Connector: Name : SENSOR-MAP Color : BLACK # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 MAP SIGNAL K1 20VT/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY K857 20BR/LG Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3502 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3503 Manifold Pressure/Vacuum Sensor: Diagrams Component ID: 300 Component : SENSOR-MAP Connector: Name : SENSOR-MAP Color : BLACK # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 MAP SIGNAL K1 20VT/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY K857 20BR/LG Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3504 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Description Manifold Pressure/Vacuum Sensor: Description and Operation Description DESCRIPTION The MAP sensor mounts to the intake manifold. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Description > Page 3507 Manifold Pressure/Vacuum Sensor: Description and Operation Operation OPERATION The MAP serves as a PCM input, using a silicon based sensing unit, to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When MAP equals Barometric pressure, the pulse width will be at maximum. Also like the cam and crank sensors, a 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5 volt and full scale is 4.5 volt. For a pressure swing of 0 - 15 psi the voltage changes 4.0 volt. The sensor is supplied a regulated 4.8 to 5.1 volts to operate the sensor. Like the cam and crank sensors ground is provided through the sensor return circuit. The MAP sensor input is the number one contributor to pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or is it in Denver at 5000 feet above sea level, because the air density changes with altitude. It will also help to correct for varying weather conditions. If a hurricane was coming through the pressure would be very, very low or there could be a real fair weather, high pressure area. This is important because as air pressure changes the barometric pressure changes. Barometric pressure and altitude have a direct inverse correlation, as altitude goes up barometric goes down. The first thing that happens as the key is rolled on, before reaching the crank position, the PCM powers up, comes around and looks at the MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure relative to altitude. Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key on. The difference between current and what it was at key on is manifold vacuum. During key On (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring known good sensor in your work area. As the altitude increases the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key On the barometric pressure needs to be updated. Any time the PCM sees Wide Open throttle, based upon TPS angle and RPM it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively. The PCM uses the MAP sensor to aid in calculating the following: - Barometric pressure - Engine load - Manifold pressure - Injector pulse-width - Spark-advance programs - Shift-point strategies (F4AC1 transmissions only, via the PCI bus) - Idle speed - Decel fuel shutoff The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 88 kPa (26 in. Hg). Barometric pressure is the pressure exerted by the atmosphere upon an object. At sea level on a standard day, no storm, barometric pressure is 101 kPa (29.92 in. Hg). For every 30.5 meters (100 feet) of altitude barometric pressure drops .33 kPa (0.10 in. Hg). If a storm goes through it can either add, high pressure, or decrease, low pressure, from what should be present for that altitude. You should make a habit of knowing what the average pressure and corresponding barometric pressure is for your area. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal Manifold Pressure/Vacuum Sensor: Service and Repair Removal 2.0/2.4L 1. Remove the air cleaner cover. 2. Disconnect the negative battery cable. 3. Disconnect the electrical connector from the MAP sensor. 4. Remove the screws from the MAP sensor. 5. Remove the MAP sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 3510 Manifold Pressure/Vacuum Sensor: Service and Repair Installation 2.0/2.4L 1. Make sure that the manifold is clean. 2. Install sensor to manifold. 3. Tighten screw. 4. Connect the electrical connector to the sensor. 5. Connect the negative battery cable. 6. Install the air cleaner cover. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 Oxygen Sensor: Locations Sensor - Oxygen 1/1 Component ID: 304 Component : SENSOR-OXYGEN 1/1 Connector: Name : SENSOR-OXYGEN 1/1 Color : GRAY # of pins : 4 Qualifier : (GAS) Pin Description Circuit 1 GROUND Z916 18BK 2 O2 1/1 HEATER CONTROL K99 20BR/OR 3 O2 1/1 RETURN K902 20BR/DG 4 O2 1/1 SIGNAL K41 20BK/DG Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 3515 Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 3516 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 3517 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 3518 Oxygen Sensor: Locations Sensor - Oxygen 1/2 Component ID: 305 Component : SENSOR-OXYGEN 1/2 Connector: Name : SENSOR-OXYGEN 1/2 Color : BLACK # of pins : 4 Qualifier : (GAS) Pin Description Circuit 1 GROUND Z924 18BK/LB 2 O2 1/2 HEATER CONTROL K299 20BR/RD 3 O2 1/2 RETURN K904 20DB/DG 4 O2 1/2 SIGNAL K141 20DB/YL Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 3519 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 3520 Oxygen Sensor: Locations 1/1 Upstream - 2.0/2.4L The upstream oxygen sensor threads into the outlet flange of the exhaust manifold. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 3521 Oxygen Sensor: Locations 1/2 Downstream - 2.0/2.4L The downstream heated oxygen sensor threads into the catalytic converter. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Sensor-Oxygen 1/1 Oxygen Sensor: Diagrams Sensor-Oxygen 1/1 Component ID: 304 Component : SENSOR-OXYGEN 1/1 Connector: Name : SENSOR-OXYGEN 1/1 Color : GRAY # of pins : 4 Qualifier : (GAS) Pin Description Circuit 1 GROUND Z916 18BK 2 O2 1/1 HEATER CONTROL K99 20BR/OR 3 O2 1/1 RETURN K902 20BR/DG 4 O2 1/1 SIGNAL K41 20BK/DG Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Sensor-Oxygen 1/1 > Page 3524 Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Sensor-Oxygen 1/1 > Page 3525 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Sensor-Oxygen 1/1 > Page 3526 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Sensor-Oxygen 1/1 > Page 3527 Oxygen Sensor: Diagrams Sensor-Oxygen 1/2 Component ID: 305 Component : SENSOR-OXYGEN 1/2 Connector: Name : SENSOR-OXYGEN 1/2 Color : BLACK # of pins : 4 Qualifier : (GAS) Pin Description Circuit 1 GROUND Z924 18BK/LB 2 O2 1/2 HEATER CONTROL K299 20BR/RD 3 O2 1/2 RETURN K904 20DB/DG 4 O2 1/2 SIGNAL K141 20DB/YL Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Sensor-Oxygen 1/1 > Page 3528 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3529 Oxygen Sensor: Application and ID - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description Oxygen Sensor: Description and Operation Description DESCRIPTION The upstream oxygen sensor threads into the outlet flange of the exhaust manifold. The downstream heated oxygen sensor threads into the system depending on emission package. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description > Page 3532 Oxygen Sensor: Description and Operation Operation OPERATION Separate upstream and downstream grounds are used on the NGC vehicles (4 Cyl.). As vehicles accumulate mileage, the catalytic convertor deteriorates. The deterioration results in a less efficient catalyst. To monitor catalytic convertor deterioration, the fuel injection system uses two heated oxygen sensors. One sensor upstream of the catalytic convertor, one downstream of the convertor. The PCM compares the reading from the sensors to calculate the catalytic convertor oxygen storage capacity and converter efficiency. Also, the PCM uses the upstream heated oxygen sensor input when adjusting injector pulse width. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the malfunction indicator lamp (MIL). The O2 sensors produce a constant 2.5 volts on NGC vehicles, depending upon the oxygen content of the exhaust gas. When a large amount of oxygen is present (caused by a lean air/fuel mixture, can be caused by misfire and exhaust leaks), the sensors produce a low voltage. When there is a lesser amount of oxygen present (caused by a rich air/fuel mixture, which can be caused by internal engine problems) it produces a higher voltage. By monitoring the oxygen content and converting it to electrical voltage, the sensors act as a rich-lean switch. The oxygen sensors are equipped with a heating element that keeps the sensors at proper operating temperature during all operating modes. Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop operation the PCM monitors the O2 sensor's input (along with other inputs) and adjusts the injector pulse width accordingly. During Open Loop operation the PCM ignores the O2 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. The NGC Controller has a common ground for the heater in the O2S. 12 volts is supplied to the heater in the O2S by the NGC controller. Both the upstream and downstream O2 sensors for NGC are pulse width modulation (PWM). NOTE: When replacing an O2 Sensor, the PCM RAM memory must be cleared, either by disconnecting the PCM C-1 connector or momentarily disconnecting the Battery negative terminal. The NGC learns the characteristics of each O2 heater element and these old values should be cleared when installing a new O2 sensor. The customer may experience driveability issues if this is not performed. UPSTREAM OXYGEN SENSOR The input from the upstream heated oxygen sensor tells the PCM the oxygen content of the exhaust gas. Based on this input, the PCM fine tunes the air-fuel ratio by adjusting injector pulse width. The sensor input switches from 2.5 to 3.5 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air-fuel mixture), the sensor produces voltage as low as 2.5 volt. When there is a lesser amount of oxygen present (rich air-fuel mixture) the sensor produces a voltage as high as 3.5 volt. By monitoring the oxygen content and converting it to electrical voltage, the sensor acts as a rich-lean switch. The heating element in the sensor provides heat to the sensor ceramic element. Heating the sensor allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop, the PCM adjusts injector pulse width based on the upstream heated oxygen sensor input along with other inputs. In Open Loop, the PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. DOWNSTREAM OXYGEN SENSOR The downstream heated oxygen sensor input is used to detect catalytic convertor deterioration. As the convertor deteriorates, the input from the downstream sensor begins to match the upstream sensor input except for a slight time delay. By comparing the downstream heated oxygen sensor input to the input from the upstream sensor, the PCM calculates catalytic convertor efficiency. This is also used to establish the upstream O2 goal voltage (switching point). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal Oxygen Sensor: Service and Repair Removal 1/1 Upstream - 2.0/2.4L 1/1 UPSTREAM - 2.0/2.4L 1. Remove the engine cover. 2. Remove the negative battery cable. 3. Disconnect electrical connector from O2 sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 3535 4. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent. 1/2 Downstream - 2.0/2.4L 1/2 DOWNSTREAM - 2.0/2.4L Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 3536 The downstream heated oxygen sensor threads into the catalytic converter. 1. Remove the negative battery cable. 2. Raise vehicle and support. 3. Disconnect electrical connector from sensor. 4. Disconnect sensor electrical harness from clips along body. 5. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 3537 Oxygen Sensor: Service and Repair Installation 1/1 Upstream - 2.0/2.4L 1/1 UPSTREAM - 2.0/2.4L 1. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite(R) 771-64 or equivalent. New sensors have compound on the threads and do not require an additional coating. Tighten the sensor to 41 Nm (30 ft. lbs.). 2. Install sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 3538 3. Connect electrical connector to sensor. 4. Install the negative battery cable. 5. Install the engine cover. 1/2 Downstream - 2.0/2.4L 1/2 DOWNSTREAM - 2.0/2.4L Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 3539 The downstream heated oxygen sensor threads into the exhaust pipe behind the catalytic converter. 1. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite(R) 771-64 or equivalent. New sensors have compound on the threads and do not require an additional coating. Tighten the sensor to 41 Nm (30 ft. lbs.). 2. Install sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent. 3. Connect sensor electrical harness to clips along body. 4. Connect electrical connector to sensor. 5. Lower vehicle. 6. Install the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Page 3540 Oxygen Sensor: Tools and Equipment FUEL O2S (Oxygen Sensor) Remover/Installer-C-4907 O2S (Oxygen Sensor) Remover/Installer - 8439 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations Component ID: 318 Component : SENSOR-VEHICLE SPEED Connector: Name : SENSOR-VEHICLE SPEED Color : BLACK # of pins : 3 Qualifier : (GAS MTX) Pin Description Circuit 1 5 VOLT SUPPLY F856 20YL/PK 2 SENSOR GROUND K914 18BR/WT 3 VEHICLE SPEED SIGNAL K75 18WT/OR Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 3544 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: Provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3547 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3548 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3549 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3550 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3551 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3552 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3553 5. Release the Secondary Terminal Lock, if required (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3554 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3555 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3556 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3557 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3558 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3559 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3560 Vehicle Speed Sensor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3561 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3562 STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3563 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3564 Vehicle Speed Sensor: Connector Views Component ID: 318 Component : SENSOR-VEHICLE SPEED Connector: Name : SENSOR-VEHICLE SPEED Color : BLACK # of pins : 3 Qualifier : (GAS MTX) Pin Description Circuit 1 5 VOLT SUPPLY F856 20YL/PK 2 SENSOR GROUND K914 18BR/WT 3 VEHICLE SPEED SIGNAL K75 18WT/OR Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3565 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Locations > Solenoid-Camshaft 1/1 Position Variable Valve Timing Solenoid: Locations Solenoid-Camshaft 1/1 Position Component ID: 325 Component : SOLENOID-CAMSHAFT 1/1 POSITION Connector: Name : SOLENOID-CAMSHAFT 1/1 POSITION Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 CMP 1/1 CONTROL K76 20LB/WT 2 FUSED MAIN RELAY OUTPUT K343 16BR/YL Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Locations > Solenoid-Camshaft 1/1 Position > Page 3570 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Locations > Solenoid-Camshaft 1/1 Position > Page 3571 Variable Valve Timing Solenoid: Locations Solenoid-Camshaft 1/2 Position Component ID: 326 Component : SOLENOID-CAMSHAFT 1/2 POSITION Connector: Name : SOLENOID-CAMSHAFT 1/2 POSITION Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 CMP 1/2 CONTROL K276 20DB/WT 2 FUSED MAIN RELAY OUTPUT K343 16BR/YL Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Locations > Solenoid-Camshaft 1/1 Position > Page 3572 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Diagrams > Solenoid-Camshaft 1/1 Position Variable Valve Timing Solenoid: Diagrams Solenoid-Camshaft 1/1 Position Component ID: 325 Component : SOLENOID-CAMSHAFT 1/1 POSITION Connector: Name : SOLENOID-CAMSHAFT 1/1 POSITION Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 CMP 1/1 CONTROL K76 20LB/WT 2 FUSED MAIN RELAY OUTPUT K343 16BR/YL Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Diagrams > Solenoid-Camshaft 1/1 Position > Page 3575 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Diagrams > Solenoid-Camshaft 1/1 Position > Page 3576 Variable Valve Timing Solenoid: Diagrams Solenoid-Camshaft 1/2 Position Component ID: 326 Component : SOLENOID-CAMSHAFT 1/2 POSITION Connector: Name : SOLENOID-CAMSHAFT 1/2 POSITION Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 CMP 1/2 CONTROL K276 20DB/WT 2 FUSED MAIN RELAY OUTPUT K343 16BR/YL Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Diagrams > Solenoid-Camshaft 1/1 Position > Page 3577 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Description and Operation > Description Variable Valve Timing Solenoid: Description and Operation Description DESCRIPTION Variable valve timing solenoid assembly. The solenoid receives pulse width modulation signal and the current is controlled within 0 ma to 1000 ma. The spool position is controllable at any position to control supply of oil between the advance and retard ports. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Description and Operation > Description > Page 3580 Variable Valve Timing Solenoid: Description and Operation Operation OPERATION There is both an Intake and an exhaust camshaft sensor on vehicles equipped with a World Engine. The variable valve timing system used on World Engines requires the exact position of both the intake and exhaust camshaft. The GPEC1 uses camshaft sensor data along with crankshaft data to determine the actual position of the camshafts. Intake and exhaust phaser oil control valves are required on World Engine vehicles using variable valve timing. The oil valves direct oil to the Intake and exhaust phasers. Oil pressure in the phasers moves the camshafts to an advanced or retarded position. To resolve this inherent conflict between optimum high and low speed valve timing, the GPEC1 controlled engine uses a variable valve timing system. The variable valve timing system advances and retards valve timing by rotating the position of both the intake and exhaust camshafts. With this system, the intake valve opening can range from 80 to 120 crankshaft degrees after Top Dead Center. Likewise, the exhaust valve opening can range from 85 to 120 crankshaft degrees before Top Dead Center. This degree of flexibility provides many benefits, including: Improved Engine Performance, Increased Fuel Economy, Improved Idle Stability and Decreased Engine Emissions. In non operating condition, the camshaft stays in lockpin position of cam phases. This is 120 degrees ATDC for intake camshaft and 120 degrees BTDC for exhaust camshaft. The variable valve timing system is electronically controlled and hydraulically operated. The GPEC1 receives information from many sensors to determine the optimum valve timing. It then pulse-width modulates oil control valves which direct oil to the cam phasers. The cam phasers use oil pressure to rotate the intake and exhaust camshafts. The rotation of the camshafts is referred to as cam phasing. Before the GPEC1 can begin commanding the camshaft phasing, several enabling conditions must be met: - The engine oil temperature must be at least -6.6° C (20° F) - The oil control valve coil temperature must be less than 140° C (284° F) - Engine speed must be at least 600 to 1000 rpm to achieve minimum oil pressure. - Battery voltage must be at least 10 volts - And there must be no camshaft or crankshaft sensor faults, engine timing faults, or oil control valve faults First we will examine variable valve timing enabling conditions, and then we will take a closer look at the inputs and outputs of the system: - Accelerator pedal position sensor - Oil temperature sensor - Map sensor - Intake cam sensor - Exhaust cam sensor - Crankshaft sensor - GPEC1 - Exhaust phaser oil control valve - Intake phaser oil control valve - Inputs - Engine control module - Outputs - Sensed battery voltage A minimum oil temperature is required to enable variable valve timing operation. Oil temperature and viscosity also have an impact on the operation of variable valve timing after start-up. Oil is used to control the movement of the camshafts. An incorrect oil viscosity could adversely affect the operation of the system or even render the system inoperative. It may even set a fault code. The accelerator pedal position sensor indicates how far the driver wants to open the throttle plate. The GPEC1 calculates an initial camshaft set point based on whether the accelerator pedal is at part throttle or wide open throttle. The MAP sensor provides information regarding engine load. Sensed battery voltage provides information regarding current system voltage. Sensed battery voltage must be at least 10 volts in order for the oil control valves to function properly. This information allows the GPEC1 to adjust camshaft timing to achieve the best fuel economy, the best engine performance or a combination of both. The hall-effect crankshaft sensor provides RPM information and determines when the number one piston is approaching Top Dead Center. The sensor generates a signal as the tone wheel, attached to the crankshaft, rotates. The tone wheel has 60 teeth minus two. When the gap, created by the missing teeth passes by the sensor, a signal is produced that indicates the number one piston is at Top Dead Center. The GPEC1 uses crankshaft sensor data along with camshaft data to determine the actual position of the camshaft. There are two hall-effect camshaft sensors on engines equipped with variable valve timing. The GPEC1 uses camshaft sensor data along with crankshaft data to determine the actual position of the camshaft. The GPEC1 individually controls each valve. It sends a pulse width modulated signal to move a spool within the outer casing of the valve. Depending upon spool movement, oil is directed through the passages to advance or retard cam timing. The oil control valve also has a special cleaning strategy at Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Description and Operation > Description > Page 3581 key-on. The cleaning strategy is known as "debris crush mode". At key-on the GPEC1 cycles the oil control valve on and off several (5) times to crush any debris in the oil control valve and prevent the spool valve from sticking. In non operating condition, the camshaft stays in lockpin position of cam phases. This is 120 degrees ATDC for intake camshaft and 120 degrees BTDC for exhaust camshaft. There are two oil control valves. One valve directs oil to the intake cam phaser, the other valve directs oil to the exhaust cam phaser. The valves are designed and function in the same manner. The outer casing of each oil valve has five oil passages. A passage for pressurized supply oil. A passage to the advance chamber of the cam phaser. A passage to the retard chamber of the cam phaser. A passage for oil return from the advance chamber of the cam phaser. A passage for oil return from the retard chamber of the cam phaser. Oil flows through the passages and applies pressure to the cam phasers to change cam timing. There are two cam phasers. One phaser controls the position of the intake camshaft. The other phaser controls the position of the exhaust camshaft. The phasers consist of a sprocket, a rotor vane, and a housing or stator. The exhaust cam phaser also consists of a front bushing and spring. We will discuss the purpose and function of the bushing and spring later. The housing is bolted and permanently fixed to the camshaft sprocket, while the rotor vane is bolted and permanently fixed to the camshaft. With this design, any movement of the rotor vane in relation to the housing will also move the camshaft. The phaser and sprocket are serviced as an assembly. Camshaft and crankshaft sensors provide feedback to the GPEC1 regarding the actual position of the camshafts. The GPEC1 then compares the actual camshaft positioning with desired positioning. If the desired positioning is not achieved within a specified time, during the second key cycle a trouble code is set. There are six new diagnostic trouble codes available to help you determine if the control circuit from the GPEC1 to the oil control valve is intact and operating properly. The codes identify whether the control circuit is open, shorted to ground, or shorted to power. Three trouble codes are related to intake camshaft positioning, the other three codes are specific to exhaust camshaft positioning. The oil control valve contains both electrical and mechanical components. It is electrically controlled by the GPEC1. The electrical current that energizes the coil results in mechanical motion of the spool valve. It is possible to verify both the electrical and mechanical operation of the valve. The oil control valve consists of a coil that is energized to move a spool within an outer casing. The condition of the coil can be tested with a Digital Volt Ohmmeter or DVOM. With the DVOM set to measure resistance, check the coil for an open, a short to ground, or excessive resistance. The correct resistance value of the coil is between 6 and 8 ohms. The mechanical operation of the oil control valve can be tested using actuator commands on the scan tool. Remove the oil control valve, then navigate to the actuator menu and select the oil control valve. Use commands to activate the valve and watch as the spool valve moves back and forth inside the casing. Because the cam phasers are hydraulically operated by engine oil, the condition of the oil is very important. The oil must be of the correct viscosity, not obstructed by debris, to maintain correct pressure. Maintaining the correct oil viscosity is critical to the operation of the variable valve timing system. The wrong oil viscosity may cause the variable valve timing to malfunction and trouble codes to set. The correct oil viscosity for this system is 5W20. Oil must be clean, unobstructed and free to flow through the variable valve timing system. Oil could become obstructed in oil passages located in the cylinder head, cylinder block, or even in the oil screen. In the event oil flow is obstructed, further diagnosis or disassembly may be required to pin point the source of the obstruction. The variable valve timing system relies on oil pressure to advance or retard the position of the camshaft. Insufficient oil pressure will adversely affect the operation of variable valve timing. The minimum oil pressure for this system is 15 psi at normal operating temperature. Though not directly used to change camshaft positioning, the oil screen is an important component of the variable valve timing system. It helps to remove debris going to the variable valve timing components. The oil screen is located in the cylinder block, immediately below the cylinder head. Oil must pass through the oil screen before entering the oil control valve. The cylinder head must be removed to service the oil screen. The intention is not to service the oil screen during vehicle life. How the cam phaser works. The cam phaser assembly has eight separate chambers; four advance chambers and four retard chambers. When camshaft advance is requested, oil enters all four advance chambers and exerts force on the rotor vane. Because the rotor vane is bolted to the camshaft, the entire camshaft profile moves along with the rotor vane. At the same time, oil is forced out of the retard chambers. When camshaft retard is requested oil enters the retard chambers to move the camshaft in the opposite direction. There is a lock pin on one side of the rotor vane that fits inside a recessed area in the housing. The lock pin ensures that the default position of the intake cam phaser is 120 crankshaft degrees full retard and the default position of the exhaust cam phaser is 120 crankshaft degrees full advance. When the engine is turned off, rotational force and inertia move the intake camshaft and rotor vane toward the retard position. The exhaust cam phaser includes a spring and bushing to work against the rotational force of the engine, allowing the exhaust cam phaser to lock in the fully advanced position. Under most conditions the cam phasers are returned to lock pin position when the engine is turned off. In the unique condition of an engine stall, which abruptly shuts off the engine, the cam phasers may not return to the lock pin position. In this case, the phasers will return to the lock pin position at the next start-up. Lock pin position is the most ideal cam timing for idle stability. When engine rpm exceeds approximately 600 to 1000 rpm, oil pressure unlocks the pins and variable valve timing resumes. Once enabling conditions are met, the GPEC1 uses input from sensors to calculate optimum valve timing. There are four preprogrammed modes from which the GPEC1 bases initial valve timing. - Starting - Idle or Part throttle - Wide open throttle - Limp-in or Default From each preprogrammed mode, the GPEC1 adjusts valve timing based on operating conditions. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Description and Operation > Description > Page 3582 GPEC1 has calculated optimum intake valve timing of 112 degrees after Top Dead Center and optimum exhaust valve timing of 97 degrees before Top Dead Center. The GPEC1 pulse width modulates the oil control valves to advance or retard the camshaft to their desired location. The spool valve inside the intake oil control valve is energized and moves to allow pressurized oil into the advance chambers of the intake cam phaser. At the same time, the spool valve inside the exhaust oil control valve is energized and moves to allow pressurized oil into the retard chambers of the exhaust cam phaser. Oil enters the advance chambers of the intake phaser and the retard chambers of the exhaust phaser. Oil pressure releases the lock pin from its locked position and pushes against the rotor vane. Both the rotor vanes are moved, advancing the intake camshaft and retarding the exhaust camshaft. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Service and Repair > Variable Valve Timing Solenoid - Removal Variable Valve Timing Solenoid: Service and Repair Variable Valve Timing Solenoid - Removal Front Solenoid 1/1 FRONT SOLENOID 1/1 1. Disconnect negative battery cable. 2. Remove engine cover. 3. Rotate hose clamp out of way. 4. Disconnect oil pressure sensor electrical connector. 5. Remove oil pressure sensor. 6. Disconnect variable valve timing solenoid electrical connector. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Service and Repair > Variable Valve Timing Solenoid - Removal > Page 3585 7. Remove variable valve timing solenoid mounting bolt. 8. Pull solenoid straight out of cylinder head. Rear Solenoid 1/2 REAR SOLENOID 1/2 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Service and Repair > Variable Valve Timing Solenoid - Removal > Page 3586 1. Disconnect negative battery cable. 2. Remove engine cover. 3. Disconnect variable valve timing solenoid electrical connector. 4. Remove variable valve timing solenoid mounting bolt. 5. Pull solenoid straight out of cylinder head. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Service and Repair > Variable Valve Timing Solenoid - Removal > Page 3587 Variable Valve Timing Solenoid: Service and Repair Variable Valve Timing Solenoid - Installation Front Solenoid 1/1 FRONT SOLENOID 1/1 1. Solenoid for front location 1/1. Note mounting tab location is different between front and rear solenoids. 2. Install solenoid into cylinder head. 3. Install mounting bolt and tighten to 12 Nm (9 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Service and Repair > Variable Valve Timing Solenoid - Removal > Page 3588 4. Install oil pressure sensor. 5. Connect electrical connector to oil pressure sensor. 6. Connect electrical connector to Variable valve timing solenoid. 7. Connect negative battery cable. 8. Install engine cover. Rear Solenoid 1/2 REAR SOLENOID 1/2 1. Rear variable valve timing solenoid. Note mounting tab location is different between front and rear solenoids. 2. Install solenoid into cylinder head. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Service and Repair > Variable Valve Timing Solenoid - Removal > Page 3589 3. Install mounting bolt and tighten to 12 Nm (9 ft. lbs.). 4. Connect electrical connector to Variable valve timing solenoid. 5. Connect negative battery cable. 6. Install engine cover. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations Component ID: 318 Component : SENSOR-VEHICLE SPEED Connector: Name : SENSOR-VEHICLE SPEED Color : BLACK # of pins : 3 Qualifier : (GAS MTX) Pin Description Circuit 1 5 VOLT SUPPLY F856 20YL/PK 2 SENSOR GROUND K914 18BR/WT 3 VEHICLE SPEED SIGNAL K75 18WT/OR Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 3593 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: Provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3596 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3597 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3598 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3599 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3600 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3601 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3602 5. Release the Secondary Terminal Lock, if required (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3603 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3604 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3605 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3606 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3607 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3608 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3609 Vehicle Speed Sensor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3610 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3611 STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3612 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3613 Vehicle Speed Sensor: Connector Views Component ID: 318 Component : SENSOR-VEHICLE SPEED Connector: Name : SENSOR-VEHICLE SPEED Color : BLACK # of pins : 3 Qualifier : (GAS MTX) Pin Description Circuit 1 5 VOLT SUPPLY F856 20YL/PK 2 SENSOR GROUND K914 18BR/WT 3 VEHICLE SPEED SIGNAL K75 18WT/OR Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3614 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Catalytic Converter Catalytic Converter: Description and Operation Catalytic Converter DESCRIPTION The combination exhaust manifold/catalytic converter is attached to the intermediate pipe using fasteners and a gasket for sealing. WARNING: The normal operating temperature of the exhaust system is very high. Therefore, never work around or attempt to service any part of the exhaust system until it is cooled. Special care should be taken when working near the catalytic converter. The temperature of the converter rises to a high level after a short period of engine operation time. CAUTION: DO NOT remove spark plug wires from plugs or by any other means short out cylinders. Failure of the catalytic converter can occur due to a temperature increase caused by unburned fuel passing through the converter. The stainless steel catalytic converter body is designed to last the life of the vehicle. Excessive heat can result in bulging or other distortion, but excessive heat will not be the fault of the converter. If unburned fuel enters the converter, overheating may occur. If a converter is heat-damaged, correct the cause of the damage at the same time the converter is replaced. Also, inspect all other components of the exhaust system for heat damage. Unleaded gasoline must be used to avoid contaminating the catalyst core. FWD vehicles use a catalytic converter located after the exhaust manifold and before the I-Pipe/Muffler assembly. AWD vehicles use a maniverter and an under floor catalytic converter. The under floor catalytic converter is located between the maniverter and the I-Pipe/muffler assembly. Diesel engine vehicles use a catalytic converter located between the turbocharger and the I-Pipe/Muffler assembly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Catalytic Converter > Page 3620 Catalytic Converter: Description and Operation Converter-Catalytic OPERATION - GAS ENGINE The three-way catalytic converter simultaneously converts three exhaust emissions into harmless gases. Specifically, HC and CO emissions are converted into water (H2O) and carbon dioxide (CO2). Oxides of Nitrogen (NOx) are converted into Nitrogen (N) and Oxygen. The three-way catalyst is most efficient in converting HC, CO and NOx at the stoichiometric air fuel ratio of 14.7:1. The oxygen content in a catalyst is important for efficient conversion of exhaust gases. When a high oxygen content (lean) air/fuel ratio is present for an extended period, oxygen content in a catalyst can reach a maximum. When a rich air/fuel ratio is present for an extended period, the oxygen content in the catalyst can become totally depleted. When this occurs, the catalyst fails to convert the gases. This is known as catalyst "punch through." Catalyst operation is dependent on its ability to store and release the oxygen needed to complete the emissions-reducing chemical reactions. As a catalyst deteriorates, its ability to store oxygen is reduced. Since the catalyst's ability to store oxygen is somewhat related to proper operation, oxygen storage can be used as an indicator of catalyst performance. Refer to the appropriate Diagnostic Information for diagnosis of a catalyst related Diagnostic Trouble Code (DTC). The combustion reaction caused by the catalyst releases additional heat in the exhaust system, causing temperature increases in the area of the reactor under severe operating conditions. Such conditions can exist when the engine misfires or otherwise does not operate at peak efficiency. Do not remove spark plug wires from plugs or by any other means short out cylinders. Failure of the catalytic converter can occur due to temperature increases caused by unburned fuel passing through the converter. This deterioration of the catalyst core can result in excessively high emission levels, noise complaints, and exhaust restrictions. Unleaded gasoline must be used to avoid ruining the catalyst core. Do not allow engine to operate above 1200 RPM in neutral for extended periods over 5 minutes. This condition may result in excessive exhaust system/floor pan temperatures because of no air movement under the vehicle. The flex joint allows flexing as the engine moves, preventing breakage that could occur from the back-and-forth motion of a transverse mounted engine. CAUTION: Due to exterior physical similarities of some catalytic converters with pipe assemblies, extreme care should be taken with replacement parts. There are internal converter differences required in some parts of the country (particularly vehicles built for States with strict emission requirements) and between model years. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service and Repair > Procedures Catalytic Converter: Procedures INSPECTION WARNING: The normal operating temperature of the exhaust system is very high. Therefore, never attempt to service any part of the exhaust system until it is cooled. Special care should be taken when working near the catalytic converter. The temperature of the converter rises to a high level after a short period of engine operation time. Check catalytic converter for a flow restriction. Visually inspect the catalytic converter element by using a borescope or equivalent. Remove oxygen sensor(s) and insert borescope. If borescope is not available, remove converter and inspect element using a flashlight. Inspect element for cracked or melted substrate. NOTE: Before replacing a catalytic converter, determine the root cause of failure. Most catalytic converter failures are caused by air, fuel or ignition problems. (Refer to Appropriate Diagnostic Information) for test procedures. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service and Repair > Procedures > Page 3623 Catalytic Converter: Removal and Replacement Under Floor Catalytic Converter UNDER FLOOR CATALYTIC CONVERTER WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER WORK AROUND OR ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATING TIME. 1. Raise vehicle on hoist and apply penetrating oil to band clamp fastener of component being removed. NOTE: Do not use petroleum-based lubricants when removing/installing muffler or exhaust pipe isolators as it may compromise the life of the part. A suitable substitute is a mixture of liquid dish soap and water. 2. Remove I-Pipe/Muffler assembly. 3. Disconnect oxygen sensor electrical connectors. NOTE: If spherical gasket is to be reused, mark orientation. 4. Remove flange bolts (3), springs and spherical gasket. 5. Remove under floor catalytic converter (4) from combination manifold/catalytic converter assembly (1). 6. Clean ends of pipes to assure mating of all parts. Discard broken or worn isolators, rusted or overused clamps, supports, and attaching parts. NOTE: When replacement is required on any component of the exhaust system, you must use original equipment parts (or their equivalent). Catalytic Converter - FWD CATALYTIC CONVERTER - FWD Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service and Repair > Procedures > Page 3624 WARNING: The normal operating temperature of the exhaust system is very high. Therefore, never attempt to service any part of the exhaust system until it is cooled. Special care should be taken when working near the catalytic converter. The temperature of the converter rises to a high level after a short period of engine operation time. NOTE: Before replacing a catalytic converter, determine the root cause of failure. Most catalytic converter failures are caused by air, fuel or ignition problems. Refer to the appropriate service diagnostic information for repair procedures. 1. Loosen intermediate pipe-to catalytic converter clamp. NOTE: Do not use petroleum-based lubricants when removing/installing muffler or exhaust pipe isolators as it may compromise the life of the part. A suitable substitute is a mixture of liquid dish soap and water. 2. Remove catalytic converter to exhaust manifold attaching fasteners and remove converter from vehicle. 3. Remove I-Pipe/Muffler assembly insulators as necessary to slide I-Pipe/Muffler assembly out of catalytic converter. 4. Remove and discard flange gasket. NOTE: When replacement is required on any component of the exhaust system, original equipment parts (or equivalent) must be used. Removal - Maniverter REMOVAL - MANIVERTER WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME. NOTE: Before replacing a catalytic converter, determine the root cause of failure. Most catalytic converter failures are caused by air, fuel or ignition problems. Refer to the appropriate service diagnostic information for repair procedures. 1. Remove under floor catalytic converter. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service and Repair > Procedures > Page 3625 NOTE: When replacement is required on any component of the exhaust system, original equipment parts (or equivalent) must be used. 2. Lower vehicle. 3. Remove secondary thermostat. 4. Remove maniverter mounting bolts. 5. Remove maniverter and gasket from the engine compartment. Under Floor Catalytic Converter UNDER FLOOR CATALYTIC CONVERTER When assembling exhaust system do not tighten clamps until components are aligned and clearances are checked. 1. Install under floor catalytic converter and the isolator supports to the underbody. 2. Position spherical gasket (2) with white side facing rear of vehicle, install springs, and bolts (3). Tighten bolts to 33 Nm (24 ft. lbs.). 3. Install I-Pipe/muffler assembly 4. Working from the front of system; align each component to maintain position and proper clearance with underbody parts. 5. Tighten band clamps to 55 Nm (40 ft. lbs.). CAUTION: Band clamps should never be tightened such that the two sides of the clamps are bottomed out against the center hourglass shaped center block. Once this occurs, the clamp band has been stretched and has lost its clamping force and must be replaced. NOTE: Maintain proper clamp orientation when replacing with new clamp. 6. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary. 7. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed. Catalytic Converter - FWD CATALYTIC CONVERTER - FWD Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service and Repair > Procedures > Page 3626 1. Position catalytic converter into I-Pipe/muffler assembly. 2. Using new gasket position catalytic converter against exhaust manifold. 3. Install flange bolts. Tighten to 29 Nm (21 ft. lbs.). 4. Working from the front of system; align each component to maintain position and proper clearance with underbody parts. 5. Tighten band clamps to 55 Nm (40 ft. lbs.). CAUTION: Band clamps should never be tightened such that the two sides of the clamps are bottomed out against the center hourglass shaped center block. Once this occurs, the clamp has lost clamping force and must be replaced. 6. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary. 7. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed. Installation - Maniverter INSTALLATION - MANIVERTER NOTE: When assembling exhaust system do not tighten clamps until all components are aligned and clearances are checked. 1. Position maniverter (1) in vehicle. Use a new flange gasket. 2. Using new gasket, install maniverter (1) and mounting bolts. Tighten bolts to 28 Nm (250 in. lbs.). 3. Install secondary thermostat. 4. Install under floor catalytic converter. 5. Working from the front of system; align each component to maintain position and proper clearance with underbody parts. 6. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary. 7. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations Canister Purge Solenoid: Locations Component ID: 328 Component : SOLENOID-EVAP PURGE Connector: Name : SOLENOID-EVAP PURGE Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 EVAP PURGE CONTROL K52 20DB/WT 2 EVAP PURGE RETURN K70 20DB/BR Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 3631 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 3632 Canister Purge Solenoid: Diagrams Component ID: 328 Component : SOLENOID-EVAP PURGE Connector: Name : SOLENOID-EVAP PURGE Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 EVAP PURGE CONTROL K52 20DB/WT 2 EVAP PURGE RETURN K70 20DB/BR Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 3633 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Description and Operation > Description Canister Purge Solenoid: Description and Operation Description DESCRIPTION All vehicles use a proportional purge solenoid. The solenoid regulates the rate of vapor flow from the EVAP canister to the intake manifold. The PCM operates the solenoid. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Description and Operation > Description > Page 3636 Canister Purge Solenoid: Description and Operation Operation OPERATION All vehicles use a proportional purge solenoid. The solenoid regulates the rate of vapor flow from the EVAP canister to the intake manifold. The PCM operates the solenoid. During the cold start warm-up period and the hot start time delay, the PCM does not energize the solenoid. When de-energized, no vapors are purged. The proportional purge solenoid operates at a frequency of 200 hz and is controlled by an engine controller circuit that senses the current being applied to the proportional purge solenoid and then adjusts that current to achieve the desired purge flow. The proportional purge solenoid controls the purge rate of fuel vapors from the vapor canister and fuel tank to the engine intake manifold. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Service and Repair > Removal Canister Purge Solenoid: Service and Repair Removal REMOVAL 1. Remove air inlet resonator assembly. 2. Remove the air cleaner box. 3. Disconnect negative battery cable. 4. Unlock and disconnect electrical connector (1) from solenoid. 5. Disconnect vacuum tubes (2) from solenoid. 6. Remove solenoid (1) from bracket by depressing clip and pulling solenoid from bracket. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Service and Repair > Removal > Page 3639 Canister Purge Solenoid: Service and Repair Installation INSTALLATION The top of the solenoid has TOP printed on it. The solenoid will not operate unless it is installed correctly. 1. Connect vacuum tube (2) to solenoid. 2. Connect electrical connector (1) to solenoid and lock. 3. Install solenoid on bracket. 4. Install the negative battery cable. 5. Install air cleaner box. 6. Install resonator assembly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations Evaporative Emission Control Canister: Locations The canister mounts to a left rear rail in the rear of the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Description and Operation > Description Evaporative Emission Control Canister: Description and Operation Description DESCRIPTION The canister mounts to a left rear rail in the rear of the vehicle. The vacuum and vapor tube connect to the top of the canister. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Description and Operation > Description > Page 3645 Evaporative Emission Control Canister: Description and Operation Operation OPERATION All vehicles use a maintenance free, evaporative (EVAP) canister. Fuel tank vapors vent into the canister. The canister temporarily holds the fuel vapors until intake manifold vacuum draws them into the combustion chamber. The Powertrain Control Module (PCM) purges the canister through the proportional purge solenoid. The PCM purges the canister at predetermined intervals and engine conditions. Purge Free Cells Purge-free memory cells are used to identify the fuel vapor content of the evaporative canister. Since the evaporative canister is not purged 100% of the time, the PCM stores information about the evaporative canister's vapor content in a memory cell. The purge-free cells are constructed similar to certain purge-normal cells. The purge-free cells can be monitored by the scan tool. The only difference between the purge-free cells and normal adaptive cells is that in purge-free, the purge is completely turned off. This gives the PCM the ability to compare purge and purge-free operation. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair > Removal Evaporative Emission Control Canister: Service and Repair Removal REMOVAL 1. Disconnect negative battery cable. 2. Raise and support vehicle. 3. Depress locking tab on vapor hose connector and pull off of canister. 4. Remove hose from ESIM module. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair > Removal > Page 3648 5. Vapor hose removed. 6. Disconnect the electrical connector from ESIM module. 7. Remove two vapor canister mounting bolts. 8. Remove assembly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair > Removal > Page 3649 Evaporative Emission Control Canister: Service and Repair Installation INSTALLATION 1. Install canister and bracket. 2. Connect filter hose to ESIM. 3. Connect vapor hose. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair > Removal > Page 3650 4. Make sure locking tab on hose connector locks in place. 5. Connect electrical connector to ESIM module. 6. Lower vehicle. 7. Connect negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Emissions Hose: > 25-002-06 > Apr > 06 > Emissions - MIL ON/DTC P0456 (EVAP Small Leak) Evaporative Emissions Hose: Customer Interest Emissions - MIL ON/DTC P0456 (EVAP Small Leak) NUMBER: 25-002-06 GROUP: Emissions DATE: April 21, 2006 NOTE: THE StarSCAN(R) MUST BE AT VERSION 6.05_5P4 OR HIGHER. SUBJECT: MIL Illumination P0456 - Evaporative System Small Leak OVERVIEW: This bulletin involves inspecting the purge solenoid hose elbow and replacing the hose harness as required. MODELS: 2007 (PM) Caliber NOTE: This bulletin applies to models equipped with a 1.8L, 2.0L, or 2.4L gasoline engine (sales code EBA, ECN, or ED3) built on or before March 30, 2006 (MDH 0330XX). SYMPTOM/CONDITION: Some vehicles built within the parameters above, may have a small cut in the lower elbow that attaches the purge solenoid to the hard tube. This cut may cause a leak that will be difficult to diagnose due to its size and location. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If DTC's P0456 - Evaporative System Small Leak or to a lesser extent P0455 - Evaporative System Large Leak is present, proceed with the Repair Procedure PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Open the hood and remove the air cleaner for access to the purge solenoid assembly. 2. Remove the purge solenoid electrical connector and disconnect the quick connect tube fittings. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Emissions Hose: > 25-002-06 > Apr > 06 > Emissions - MIL ON/DTC P0456 (EVAP Small Leak) > Page 3659 3. Remove the purge solenoid assembly (tubes attached) by disconnecting the solenoid from its mounting bracket (Fig. 1). 4. Closely inspect the lower rubber elbow that attaches to the purge solenoid. (Fig. 2). 5. If a witness mark or cut/puncture is found, replace the Hose Harness with pn 05273420AB. Carefully remove the damaged hose from the solenoid. Use a small amount of soapy water to make replacement hose installation onto the purge solenoid easier. POLICY: Reimbursable within the provisions of the warranty. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Emissions Hose: > 25-002-06 > Apr > 06 > Emissions - MIL ON/DTC P0456 (EVAP Small Leak) > Page 3660 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emissions Hose: > 25-002-06 > Apr > 06 > Emissions - MIL ON/DTC P0456 (EVAP Small Leak) Evaporative Emissions Hose: All Technical Service Bulletins Emissions - MIL ON/DTC P0456 (EVAP Small Leak) NUMBER: 25-002-06 GROUP: Emissions DATE: April 21, 2006 NOTE: THE StarSCAN(R) MUST BE AT VERSION 6.05_5P4 OR HIGHER. SUBJECT: MIL Illumination P0456 - Evaporative System Small Leak OVERVIEW: This bulletin involves inspecting the purge solenoid hose elbow and replacing the hose harness as required. MODELS: 2007 (PM) Caliber NOTE: This bulletin applies to models equipped with a 1.8L, 2.0L, or 2.4L gasoline engine (sales code EBA, ECN, or ED3) built on or before March 30, 2006 (MDH 0330XX). SYMPTOM/CONDITION: Some vehicles built within the parameters above, may have a small cut in the lower elbow that attaches the purge solenoid to the hard tube. This cut may cause a leak that will be difficult to diagnose due to its size and location. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If DTC's P0456 - Evaporative System Small Leak or to a lesser extent P0455 - Evaporative System Large Leak is present, proceed with the Repair Procedure PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Open the hood and remove the air cleaner for access to the purge solenoid assembly. 2. Remove the purge solenoid electrical connector and disconnect the quick connect tube fittings. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emissions Hose: > 25-002-06 > Apr > 06 > Emissions - MIL ON/DTC P0456 (EVAP Small Leak) > Page 3666 3. Remove the purge solenoid assembly (tubes attached) by disconnecting the solenoid from its mounting bracket (Fig. 1). 4. Closely inspect the lower rubber elbow that attaches to the purge solenoid. (Fig. 2). 5. If a witness mark or cut/puncture is found, replace the Hose Harness with pn 05273420AB. Carefully remove the damaged hose from the solenoid. Use a small amount of soapy water to make replacement hose installation onto the purge solenoid easier. POLICY: Reimbursable within the provisions of the warranty. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emissions Hose: > 25-002-06 > Apr > 06 > Emissions - MIL ON/DTC P0456 (EVAP Small Leak) > Page 3667 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Locations Leak Detector: Locations Component ID: 342 Component : SWITCH-EVAP SYSTEM MONITOR Connector: Name : SWITCH-EVAP SYSTEM MONITOR Color : BLACK # of pins : 2 Qualifier : (EXCEPT EXPORT) Pin Description Circuit 1 GROUND Z965 20BK Pin Description Circuit 1 GROUND Z965 20BK/GY 2 ESM SIGNAL K107 18VT/LB 2 ESM SIGNAL K107 20VT/LB Component Location - 58 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Locations > Page 3671 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Locations > Page 3672 Leak Detector: Diagrams Component ID: 342 Component : SWITCH-EVAP SYSTEM MONITOR Connector: Name : SWITCH-EVAP SYSTEM MONITOR Color : BLACK # of pins : 2 Qualifier : (EXCEPT EXPORT) Pin Description Circuit 1 GROUND Z965 20BK Pin Description Circuit 1 GROUND Z965 20BK/GY 2 ESM SIGNAL K107 18VT/LB 2 ESM SIGNAL K107 20VT/LB Component Location - 58 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Locations > Page 3673 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Description and Operation Leak Detection Pump: Description and Operation OPERATION SYSTEM The ESIM (Evaporative System Integrity Monitor) is very similar to the NVLD. However, the design of the ESIM has been simplified and unlike the NVLD the ESIM does not require a solenoid. The ESIM mounts directly to the canister, eliminating the need for a mounting bracket. It is critical that the ESIM is mounted vertically. On vehicles where the canister is mounted on an angle, the ESIM requires an adaptor to maintain a vertical position. When the ESIM is installed vertically, the electrical connector is in the 3 o'clock position. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Description and Operation > Page 3677 EXPLODED VIEW The ESIM assembly consists of a housing, a small weight and a large weight that serve as check valves, a diaphragm, a switch and a cover. There is one large weight and one small weight check valve in the ESIM assembly. A seal is attached at the end of each weighted check valve. The large weight check valve seals for pressure. The small weight check valve seals for vacuum. The weighted check valves are contained within the ESIM housing. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Description and Operation > Page 3678 CUT AWAY OF MODULE The ESIM (Evaporative System Integrity Monitor), while physically different than the NVLD system, performs the same basic function as the NVLD does - controlling evaporative emissions. The ESIM has been simplified because the solenoid used on the NVLD is not used on the ESIM. The ESIM consists of housing, two check valves (sometimes referred to as weights), a diaphragm, a switch and a cover. The larger check valve seals for pressure and the smaller one seals for vacuum. During refueling, pressure is built up in the evaporative system. When pressure reaches approximately .5 inches of water, the large check valve unseats and pressure vents to the fresh air filter. Conversely, when the system cools and the resulting vacuum lifts the small check valve from its seat and allows fresh air to enter the system and relieve the vacuum condition. When a calibrated amount of vacuum is achieved in the evaporative system, the diaphragm is pulled inward, pushing on the spring and closing the contacts. The ESIM conducts test on the evaporative system as follows: An engine off, non-intrusive test for small leaks and an engine running, intrusive test for medium/large leaks. The ESIM weights seal the evap. system during engine off conditions. If the evap. system is sealed, it will be pulled into a vacuum, either due to the cool down from operating temperature or diurnal ambient temperature cycling. When the vacuum in the system exceeds about 1 inch H20, the vacuum switch closes. The switch closure sends a signal to the GPEC1. In order to pass the non-intrusive small leak test, the ESIM switch must close within a calculated amount of time and within a specified amount of key-off events. If the ESIM switch does not close as specified, the test is considered inconclusive and the intrusive engine running test will be run during the next key-on cycle. This intrusive test will run on the next cold engine running condition. Conditions for running the intrusive test are: - After the vehicle is started, the engine coolant temperature must be within 10° C (50°F) of ambient to indicate a cold start. - The fuel level must be between 12% and 88%. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Description and Operation > Page 3679 - The engine must be in closed loop. - Manifold vacuum must be greater than a minimum specified value. - Ambient temperature must be between 4° C and 37° C (39° F and 98° F) and the elevation level must be below 8500 feet. The test is accomplished by the GPEC1 activating the purge solenoid to create a vacuum in the evaporative system. The GPEC1 then measures the amount of time it takes for the vacuum to dissipate. This is known as the vacuum decay method. If the switch opens quickly a large leak is recorded. If the switch opens after a predetermined amount of time, then the small leak matures. If the switch does not close, then a general evaporative failure is recorded. The purge monitor tests the integrity of the hose attached between the purge valve and throttle body/intake. The purge monitor is a two stage test and it runs only after the evaporative system passes the small leak test. Even when all of the thresholds are met, a small leak wont be recorded until after the medium/large leak monitor has been run. This is accomplished by the GPEC1 activating the purge solenoid to create a vacuum in the evaporative system. The GPEC1 then measures the amount of time it takes for the vacuum to dissipate. This is known as the vacuum decay method. If the switch opens quickly a large leak is recorded. If the switch opens after a predetermined amount of time, then the small leak matures. If the medium/large leak test runs and the ESIM switch doesn't close, a general evaporative test is run. The purge solenoid is activated for approximately 10 seconds, increasing the amount of vacuum in the system. IF the ESIM switch closes after the extended purge activation, a large leak fault is generated. If the switch doesn't close, a general evaporative system fault is generated. The purge monitor tests the integrity of the hose attached between the purge valve and throttle body/intake. The purge monitor is a two stage test and it runs only after the evaporative system passes the small leak test. Stage one of the purge monitor is non-intrusive. GPEC1 monitors the purge vapor ratio. If the ratio is above a calibrated specification, the monitor passes. Stage two is an intrusive test and it runs only if stage one fails. During the stage two test, the GPEC commands the purge solenoid to flow at a specified rate to force the purge vapor ratio to update. The vapor ratio is compared to a calibrated specification and if it is less than specified, a one-trip failure is recorded. The ESIM switch stuck closed monitor checks to see if the switch is stuck closed. This is a power down test that runs at key-off; when the GPEC1 sees 0 rpms, the purge solenoid is energized for a maximum of 30 seconds, venting any vacuum trapped in the evaporative system. If the switch opens or was open before the test began, the monitor passes. If the switch doesn't open, the monitor fails. This is a two-trip MIL. The star scan tool can be used to force the ESIM switch stick closed monitor to run. The GPEC1 also uses the ESIM to detect a loose or missing gas cap. The GPEC1 controller looks for a change in the fuel level (25% minimum) and then gas cap is loose or missing. If a medium/large leak is detected, a loose gas cap light illuminates and a pending one-trip fault code is set. On the GPEC1, this is a three-trip fault before the code matures. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Description and Operation EGR Cooler: Description and Operation DESCRIPTION The EGR cooler (7) cools recirculated exhaust gasses to reduce combustion temperature and a greater mass of exhaust gases can thus be circulated. There is less nitrogen oxides as a result. The EGR cooler (7) allows the engine and catalytic converter to reach their operating temperature quickly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Removal EGR Cooler: Service and Repair Removal REMOVAL 1. Remove engine cover. 2. Drain cooling system. 3. Remove EGR cooler coolant hoses (8). 4. Remove EGR cooler to exhaust manifold tube (11). 5. Remove EGR cooler to EGR valve tube (1). 6. Remove EGR cooler mounting nuts (6). 7. Remove EGR cooler (7). 8. Remove the bypass valve mounting screws (3). 9. Separate the bypass valve assembly from the EGR cooler body (5). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Removal > Page 3686 EGR Cooler: Service and Repair Installation INSTALLATION 1. Using a new gasket, position the bypass valve assembly to the EGR cooler body (5). Tighten screws to 10 Nm (88 in. lbs.). 2. Position EGR cooler (7) and install mounting screws. Tighten to 10 Nm (88 in. lbs.). 3. Install EGR cooler to exhaust manifold tube (11). Tighten bolts to 20 Nm (14 ft. lbs.) and nuts to 20 Nm (14 ft. lbs.). 4. Install EGR cooler to EGR valve tube (1). Tighten bolts to 20 Nm (14 ft. lbs.). 5. Install coolant hoses. 6. Install vacuum line. 7. Fill cooling system. 8. Install engine cover. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations Positive Crankcase Ventilation Valve: Locations It threads into the valve cover. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Description and Operation > Description Positive Crankcase Ventilation Valve: Description and Operation Description DESCRIPTION It threads into the valve cover. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Description and Operation > Description > Page 3693 Positive Crankcase Ventilation Valve: Description and Operation Operation OPERATION When the engine is not operating or during an engine backfire, the spring forces the plunger back against the seat. This prevents vapors from flowing through the valve. When the engine is at idle or cruising, high manifold vacuum is present. At these times manifold vacuum is able to completely compress the spring and pull the plunger to the top of the valve. In this position there is minimal vapor flow through the valve. During periods of moderate intake manifold vacuum the plunger is only pulled part way back from the inlet. This results in maximum vapor flow through the valve. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Service and Repair > Removal Positive Crankcase Ventilation Valve: Service and Repair Removal REMOVAL 1. Remove the engine cover. 2. Remove the hose from the PCV valve. 3. Unscrew the PCV valve. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Service and Repair > Removal > Page 3696 Positive Crankcase Ventilation Valve: Service and Repair Installation INSTALLATION 1. Lubricate the O-ring on the valve. 2. Install the PCV valve and tighten the valve to 8.1 Nm (72 in. lbs.). 3. Install the hose. 4. Install engine cover. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL SYSTEM PRESSURE Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 3701 Fuel Pressure: Testing and Inspection *CHECKING THE FUEL DELIVERY SYSTEM For a complete wiring diagram refer to Diagrams/Electrical. Diagnostic Test 1. CHECKING THE FUEL PUMP OPERATION Turn the ignition on. NOTE: Diagnose and repair any fuel pump control circuit or relay DTCs before continuing with this test. With a scan tool, actuate the fuel pump control to ON (100%). NOTE: It may be necessary to use a mechanics stethoscope in the next step. Listen for fuel pump operation at the fuel tank. The fuel pump should operate smoothly, without excessive noise. If necessary, compare to a known good vehicle of similar year, make, and model. NOTE: If the pump has excessive noise or grinding, the pump should be replaced. caution: Stop all actuation tests before continuing. Is the fuel pump operating when actuated? Yes - Go to 2 No - Go to 7 2. CHECKING THE FUEL PRESSURE Turn the ignition off. WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in personal injury or death. Install a fuel pressure gauge on the fuel rail. Turn the ignition on. With the scan tool, actuate the fuel pump relay control. Observe the fuel pressure gauge. NOTE: The fuel pressure specification is 407 KPa ± 34 KPa (59 psi ± 5 psi). caution: Stop all actuation tests before continuing. Select the conclusion that best matches the result of the test: Fuel pressure is within the stated specification - Test complete. Fuel pressure is below the stated specification - Go to 3 Fuel pressure is above the stated specification - Replace the fuel filter/pressure regulator. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 3702 - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 3. RESTRICTED FUEL SUPPLY LINE Turn the ignition off. WARNING: The fuel system is under a constant pressure, even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in personal injury or death. Raise vehicle on hoist, and disconnect the fuel pressure line at the fuel pump module. Install special 5/16 fuel line adapter tool #6539 between disconnected fuel line and the fuel pump module. Attach a fuel pressure test gauge to the T fitting on tool #6539. Turn the ignition on. With the scan tool, actuate the fuel pump relay control. Observe the fuel pressure gauge. NOTE: Fuel pressure specification is 407 KPa ± 34 KPa (59 psi ± 5 psi). caution: Stop all actuation tests before proceeding. Is the fuel pressure within specification? Yes - Repair or replace fuel supply line as necessary. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 4 4. SADDLE FUEL TANK Is the vehicle equipped with a saddle type fuel tank? Yes - Go to 5 No - Go to 6 5. FUEL TANK SIPHON HOSE OR FUEL LINE RESTRICTED OR DAMAGED Turn the ignition off. WARNING: The fuel system is under a constant pressure, even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in personal injury or death. Gain access to the fuel pump module and the fuel tank module. Inspect the fuel line and siphon hose between the fuel pump module and the fuel tank module. Look for disconnected or damaged lines and hoses. Inspect the fuel pressure regulator for damage or a condition that might cause a fuel flow problem. Make sure that it is seated in the module properly. Were any problems found? Yes - Repair as necessary. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 3703 - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 6 6. FUEL PUMP INLET STRAINER Turn the ignition off. WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in personal injury or death. Remove the fuel pump module and inspect the fuel inlet strainer for damage or a condition that might cause a fuel flow problem. Were any problems found? Yes - Replace the Fuel Pump Inlet Strainer. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Replace the Fuel Pump Module. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 7. FUEL PUMP GROUND CIRCUIT OPEN OR HIGH RESISTANCE Turn the ignition off. Disconnect the Fuel Pump Module harness connector. Using a 12 volt test light connected to 12 volts, check the Fuel Pump Motor Ground circuit at the Fuel Pump Module harness connector. NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated and bright? Yes - Replace the Fuel Pump Module. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Repair the Fuel Pump Ground circuit for an open circuit or high resistance. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE PROCEDURE 1. Remove lower rear seat cushion. 2. Remove the fuel pump module cover. 3. Disconnect the electrical connector for fuel pump module. 4. Start and run engine until it stalls. 5. Attempt restarting engine until it will no longer run. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Page 3707 6. Turn ignition key to OFF position. 7. Disconnect negative battery cable. 8. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory. The scan tool must be used to erase a DTC. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by manufacturer Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Component ID: 281 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 APP SIGNAL 2 K29 20WT/BR 2 APP SENSOR GROUND 2 K400 20BR/VT 3 5 VOLT SUPPLY K854 20VT/BR 3 5 VOLT SUPPLY K858 20BR/GY 4 APP SIGNAL 1 K23 20BR/OR 5 APP SENSOR GROUND 1 K167 20BR/YL 6 5 VOLT SUPPLY K852 20BR/VT 6 5 VOLT SUPPLY F856 20YL/PK Component Location - 44 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3714 Component Location - 47 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3715 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3716 Accelerator Pedal Position Sensor: Diagrams Component ID: 281 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 APP SIGNAL 2 K29 20WT/BR 2 APP SENSOR GROUND 2 K400 20BR/VT 3 5 VOLT SUPPLY K854 20VT/BR 3 5 VOLT SUPPLY K858 20BR/GY 4 APP SIGNAL 1 K23 20BR/OR 5 APP SENSOR GROUND 1 K167 20BR/YL 6 5 VOLT SUPPLY K852 20BR/VT 6 5 VOLT SUPPLY F856 20YL/PK Component Location - 44 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3717 Component Location - 47 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3718 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3719 Accelerator Pedal Position Sensor: Description and Operation DESCRIPTION The Accelerator Pedal Position Sensor (APPS) is a variable resistor that provides the PCM with an input signal (voltage). The signal represents pedal angle position. As the position of the accelerator pedal changes, the resistance of the APPS changes. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal Accelerator Pedal Position Sensor: Service and Repair Removal REMOVAL 1. Disconnect negative battery cable. 2. Disconnect the electrical connector from the module. 3. Remove the mounting nuts. 4. Remove assembly from the mounting studs. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal > Page 3722 Accelerator Pedal Position Sensor: Service and Repair Installation INSTALLATION 1. Install APPS module. 2. Tighten the mounting nuts. 3. Connect electrical connector. 4. Connect negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal Air Filter Element: Service and Repair Removal REMOVAL 1. Turn lock retainers (5) and remove fresh air inlet (2) from air cleaner housing (1). 2. Disconnect intake air temperature sensor connector (4). 3. Remove air inlet tube (5) from air cleaner housing (1). 4. Unfasten clasps (2) on sides of air cleaner housing cover. 5. Pull air cleaner cover (1) aside. 6. Remove filter element (3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal > Page 3728 7. If necessary, clean the inside of the air cleaner housing (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal > Page 3729 Air Filter Element: Service and Repair Installation INSTALLATION 1. Install new filter element. 2. Place cover over air cleaner housing. Snap clasps (2) in place. 3. Install air inlet tube (5). 4. Connect intake air temperature sensor connector (4). 5. Install fresh air inlet (2) on air cleaner housing (1) and lock retainers (5). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 14-001-06 > Jan > 06 > Fuel System MIL ON/DTC P0457 Set Fuel Filler Cap: Customer Interest Fuel System - MIL ON/DTC P0457 Set NUMBER: 14-001-06 GROUP: 14 - Fuel System DATE: January 21, 2006 SUBJECT: Loose Fuel Cap Message or MIL Illumination for Diagnostic Trouble Code P0457 EVAP System - Loose Fuel Cap MODELS: 2005 - 2006 (ND) Dakota 2005 - 2006 (CS) Pacifica 2006 (DR/DH) Ram Truck 2005 - 2006 (HB) Durango 2005 - 2006 (KJ) Liberty 2006 (LX) 300/Magnum/Charger 2006 (PT) PT Cruiser 2007 (PM) Caliber 2006 (RS) Town & Country/Caravan/Voyager 2006 (TJ) Wrangler 2005 - 2006 (WK) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. NOTE: Do not replace the gas cap if only DTC P0457 - Evap System - Loose Fuel Cap is present. DISCUSSION: Starting with the introduction of 2005 model year vehicles a new diagnostic trouble code (DTC) P0457 - Evap System - Loose Fuel Cap was introduced. Also added to some vehicles was an instrument cluster message in the odometer display or message center (EVIC) that alerts the driver that the gas cap is loose. The PCM monitors the fuel level for a "significant" change in either direction and remembers that this has recently occurred. A loose fuel cap DTC, cluster message or message center message matures when the check for the EVAP system large leak condition fails after the fuel level change event. If a leak of greater than 0.090" is observed after a fuel level change, a loose cap diagnostic single trip failure is stored and the cluster message or message center message is displayed even though a DTC may not yet be present. DTC P0457 - Evap System - Loose Fuel Cap is stored and the MIL illuminated after 2 cold start failures of the large leak diagnostic checks following a fuel change event. Only the passing of one of the 3 EVAP system diagnostic routines large leak, small leak or loose gas cap) by the PCM will validate that the cap is no longer loose and turn off the MIL light or message. For 2007 model vehicles DTC P0457 - Evap System - Loose Fuel Cap will be stored and the MIL illuminated after 3 cold starts. To temporarily clear the gas cap loose message from the odometer or message center press the reset button on the odometer or message center while the message is being displayed. This clears the message for the current key cycle only. NOTE: The above works for all vehicles except, 2005 - 2006 Grand Cherokee or Commander. For these, the scantool must be used) To clear the gas cap loose message from the odometer or message center ensure the gas cap is tight and let the vehicle run the small leak diagnostic Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 14-001-06 > Jan > 06 > Fuel System MIL ON/DTC P0457 Set > Page 3738 routine. The small leak diagnostic routine will pass a sealed system after an 8 hour soak and a negative 3° C change in fuel temperature from the last key cycle. NOTE: A heated garage may effect the small leak diagnostic routine. To clear the gas cap loose message from the odometer or message center and matured DTC (MIL light) diagnose and repair the leak and then erase DTC's with the DRBIII(R)/StarSCAN(TM) scantool NOTE: The DRBIII(R)/StarSCAN(TM) scantool may be used to reset the Loose Cap message. Select the PCM Reset function on StarSCAN(TM) (version 6.05_SPI or higher) or the Clear PCM Batt Disconnect function on DRB III(R). Disconnecting and reconnecting the battery will also clear the message. If a gas cap loose message is displayed or DTC P0457 - Evap System - Loose Fuel Cap is set without P0455 - Evap System Large Leak then ensure the gas cap it tight, no further service action is required. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 14-001-06 > Jan > 06 > Fuel System - MIL ON/DTC P0457 Set Fuel Filler Cap: All Technical Service Bulletins Fuel System - MIL ON/DTC P0457 Set NUMBER: 14-001-06 GROUP: 14 - Fuel System DATE: January 21, 2006 SUBJECT: Loose Fuel Cap Message or MIL Illumination for Diagnostic Trouble Code P0457 EVAP System - Loose Fuel Cap MODELS: 2005 - 2006 (ND) Dakota 2005 - 2006 (CS) Pacifica 2006 (DR/DH) Ram Truck 2005 - 2006 (HB) Durango 2005 - 2006 (KJ) Liberty 2006 (LX) 300/Magnum/Charger 2006 (PT) PT Cruiser 2007 (PM) Caliber 2006 (RS) Town & Country/Caravan/Voyager 2006 (TJ) Wrangler 2005 - 2006 (WK) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. NOTE: Do not replace the gas cap if only DTC P0457 - Evap System - Loose Fuel Cap is present. DISCUSSION: Starting with the introduction of 2005 model year vehicles a new diagnostic trouble code (DTC) P0457 - Evap System - Loose Fuel Cap was introduced. Also added to some vehicles was an instrument cluster message in the odometer display or message center (EVIC) that alerts the driver that the gas cap is loose. The PCM monitors the fuel level for a "significant" change in either direction and remembers that this has recently occurred. A loose fuel cap DTC, cluster message or message center message matures when the check for the EVAP system large leak condition fails after the fuel level change event. If a leak of greater than 0.090" is observed after a fuel level change, a loose cap diagnostic single trip failure is stored and the cluster message or message center message is displayed even though a DTC may not yet be present. DTC P0457 - Evap System - Loose Fuel Cap is stored and the MIL illuminated after 2 cold start failures of the large leak diagnostic checks following a fuel change event. Only the passing of one of the 3 EVAP system diagnostic routines large leak, small leak or loose gas cap) by the PCM will validate that the cap is no longer loose and turn off the MIL light or message. For 2007 model vehicles DTC P0457 - Evap System - Loose Fuel Cap will be stored and the MIL illuminated after 3 cold starts. To temporarily clear the gas cap loose message from the odometer or message center press the reset button on the odometer or message center while the message is being displayed. This clears the message for the current key cycle only. NOTE: The above works for all vehicles except, 2005 - 2006 Grand Cherokee or Commander. For these, the scantool must be used) To clear the gas cap loose message from the odometer or message center ensure the gas cap is tight and let the vehicle run the small leak diagnostic Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 14-001-06 > Jan > 06 > Fuel System - MIL ON/DTC P0457 Set > Page 3744 routine. The small leak diagnostic routine will pass a sealed system after an 8 hour soak and a negative 3° C change in fuel temperature from the last key cycle. NOTE: A heated garage may effect the small leak diagnostic routine. To clear the gas cap loose message from the odometer or message center and matured DTC (MIL light) diagnose and repair the leak and then erase DTC's with the DRBIII(R)/StarSCAN(TM) scantool NOTE: The DRBIII(R)/StarSCAN(TM) scantool may be used to reset the Loose Cap message. Select the PCM Reset function on StarSCAN(TM) (version 6.05_SPI or higher) or the Clear PCM Batt Disconnect function on DRB III(R). Disconnecting and reconnecting the battery will also clear the message. If a gas cap loose message is displayed or DTC P0457 - Evap System - Loose Fuel Cap is set without P0455 - Evap System Large Leak then ensure the gas cap it tight, no further service action is required. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Description and Operation > Description Fuel Filler Cap: Description and Operation Description DESCRIPTION The plastic fuel fill cap is threaded/quarter turn onto the end of the fuel filler tube. It's purpose is to retain vapors and fuel in the fuel tank. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Description and Operation > Description > Page 3747 Fuel Filler Cap: Description and Operation Operation OPERATION The fuel filler cap incorporates a two-way relief valve that is closed to atmosphere during normal operating conditions. The relief valve is calibrated to open when a pressure of 17 kPa (2.5 psi) or vacuum of 3 kPa (12 in. Hg) occurs in the fuel tank. When the pressure or vacuum is relieved, the valve returns to the normally closed position. CAUTION: Remove the fuel filler cap to release fuel tank pressure before disconnecting any fuel system component. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap Warning Indicator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap Warning Indicator: > 14-001-06 > Jan > 06 > Fuel System - MIL ON/DTC P0457 Set Fuel Filler Cap Warning Indicator: Customer Interest Fuel System - MIL ON/DTC P0457 Set NUMBER: 14-001-06 GROUP: 14 - Fuel System DATE: January 21, 2006 SUBJECT: Loose Fuel Cap Message or MIL Illumination for Diagnostic Trouble Code P0457 EVAP System - Loose Fuel Cap MODELS: 2005 - 2006 (ND) Dakota 2005 - 2006 (CS) Pacifica 2006 (DR/DH) Ram Truck 2005 - 2006 (HB) Durango 2005 - 2006 (KJ) Liberty 2006 (LX) 300/Magnum/Charger 2006 (PT) PT Cruiser 2007 (PM) Caliber 2006 (RS) Town & Country/Caravan/Voyager 2006 (TJ) Wrangler 2005 - 2006 (WK) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. NOTE: Do not replace the gas cap if only DTC P0457 - Evap System - Loose Fuel Cap is present. DISCUSSION: Starting with the introduction of 2005 model year vehicles a new diagnostic trouble code (DTC) P0457 - Evap System - Loose Fuel Cap was introduced. Also added to some vehicles was an instrument cluster message in the odometer display or message center (EVIC) that alerts the driver that the gas cap is loose. The PCM monitors the fuel level for a "significant" change in either direction and remembers that this has recently occurred. A loose fuel cap DTC, cluster message or message center message matures when the check for the EVAP system large leak condition fails after the fuel level change event. If a leak of greater than 0.090" is observed after a fuel level change, a loose cap diagnostic single trip failure is stored and the cluster message or message center message is displayed even though a DTC may not yet be present. DTC P0457 - Evap System - Loose Fuel Cap is stored and the MIL illuminated after 2 cold start failures of the large leak diagnostic checks following a fuel change event. Only the passing of one of the 3 EVAP system diagnostic routines large leak, small leak or loose gas cap) by the PCM will validate that the cap is no longer loose and turn off the MIL light or message. For 2007 model vehicles DTC P0457 - Evap System - Loose Fuel Cap will be stored and the MIL illuminated after 3 cold starts. To temporarily clear the gas cap loose message from the odometer or message center press the reset button on the odometer or message center while the message is being displayed. This clears the message for the current key cycle only. NOTE: The above works for all vehicles except, 2005 - 2006 Grand Cherokee or Commander. For these, the scantool must be used) To clear the gas cap loose message from the odometer or message center ensure the gas cap is tight and let the vehicle run the small leak diagnostic Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap Warning Indicator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap Warning Indicator: > 14-001-06 > Jan > 06 > Fuel System - MIL ON/DTC P0457 Set > Page 3756 routine. The small leak diagnostic routine will pass a sealed system after an 8 hour soak and a negative 3° C change in fuel temperature from the last key cycle. NOTE: A heated garage may effect the small leak diagnostic routine. To clear the gas cap loose message from the odometer or message center and matured DTC (MIL light) diagnose and repair the leak and then erase DTC's with the DRBIII(R)/StarSCAN(TM) scantool NOTE: The DRBIII(R)/StarSCAN(TM) scantool may be used to reset the Loose Cap message. Select the PCM Reset function on StarSCAN(TM) (version 6.05_SPI or higher) or the Clear PCM Batt Disconnect function on DRB III(R). Disconnecting and reconnecting the battery will also clear the message. If a gas cap loose message is displayed or DTC P0457 - Evap System - Loose Fuel Cap is set without P0455 - Evap System Large Leak then ensure the gas cap it tight, no further service action is required. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap Warning Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap Warning Indicator: > 14-001-06 > Jan > 06 > Fuel System - MIL ON/DTC P0457 Set Fuel Filler Cap Warning Indicator: All Technical Service Bulletins Fuel System - MIL ON/DTC P0457 Set NUMBER: 14-001-06 GROUP: 14 - Fuel System DATE: January 21, 2006 SUBJECT: Loose Fuel Cap Message or MIL Illumination for Diagnostic Trouble Code P0457 EVAP System - Loose Fuel Cap MODELS: 2005 - 2006 (ND) Dakota 2005 - 2006 (CS) Pacifica 2006 (DR/DH) Ram Truck 2005 - 2006 (HB) Durango 2005 - 2006 (KJ) Liberty 2006 (LX) 300/Magnum/Charger 2006 (PT) PT Cruiser 2007 (PM) Caliber 2006 (RS) Town & Country/Caravan/Voyager 2006 (TJ) Wrangler 2005 - 2006 (WK) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. NOTE: Do not replace the gas cap if only DTC P0457 - Evap System - Loose Fuel Cap is present. DISCUSSION: Starting with the introduction of 2005 model year vehicles a new diagnostic trouble code (DTC) P0457 - Evap System - Loose Fuel Cap was introduced. Also added to some vehicles was an instrument cluster message in the odometer display or message center (EVIC) that alerts the driver that the gas cap is loose. The PCM monitors the fuel level for a "significant" change in either direction and remembers that this has recently occurred. A loose fuel cap DTC, cluster message or message center message matures when the check for the EVAP system large leak condition fails after the fuel level change event. If a leak of greater than 0.090" is observed after a fuel level change, a loose cap diagnostic single trip failure is stored and the cluster message or message center message is displayed even though a DTC may not yet be present. DTC P0457 - Evap System - Loose Fuel Cap is stored and the MIL illuminated after 2 cold start failures of the large leak diagnostic checks following a fuel change event. Only the passing of one of the 3 EVAP system diagnostic routines large leak, small leak or loose gas cap) by the PCM will validate that the cap is no longer loose and turn off the MIL light or message. For 2007 model vehicles DTC P0457 - Evap System - Loose Fuel Cap will be stored and the MIL illuminated after 3 cold starts. To temporarily clear the gas cap loose message from the odometer or message center press the reset button on the odometer or message center while the message is being displayed. This clears the message for the current key cycle only. NOTE: The above works for all vehicles except, 2005 - 2006 Grand Cherokee or Commander. For these, the scantool must be used) To clear the gas cap loose message from the odometer or message center ensure the gas cap is tight and let the vehicle run the small leak diagnostic Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap Warning Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap Warning Indicator: > 14-001-06 > Jan > 06 > Fuel System - MIL ON/DTC P0457 Set > Page 3762 routine. The small leak diagnostic routine will pass a sealed system after an 8 hour soak and a negative 3° C change in fuel temperature from the last key cycle. NOTE: A heated garage may effect the small leak diagnostic routine. To clear the gas cap loose message from the odometer or message center and matured DTC (MIL light) diagnose and repair the leak and then erase DTC's with the DRBIII(R)/StarSCAN(TM) scantool NOTE: The DRBIII(R)/StarSCAN(TM) scantool may be used to reset the Loose Cap message. Select the PCM Reset function on StarSCAN(TM) (version 6.05_SPI or higher) or the Clear PCM Batt Disconnect function on DRB III(R). Disconnecting and reconnecting the battery will also clear the message. If a gas cap loose message is displayed or DTC P0457 - Evap System - Loose Fuel Cap is set without P0455 - Evap System Large Leak then ensure the gas cap it tight, no further service action is required. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE PROCEDURE 1. Remove lower rear seat cushion. 2. Remove the fuel pump module cover. 3. Disconnect the electrical connector for fuel pump module. 4. Start and run engine until it stalls. 5. Attempt restarting engine until it will no longer run. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Page 3767 6. Turn ignition key to OFF position. 7. Disconnect negative battery cable. 8. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory. The scan tool must be used to erase a DTC. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 Fuel Injector: Locations Injector-Fuel 1 Component ID: 110 Component : INJECTOR-FUEL 1 Connector: Name : INJECTOR-FUEL 1 Color : BLACK # of pins : 2 Qualifier : (DIESEL) Pin Description Circuit 1 FUEL INJECTOR HIGH-SIDE COMMON K663 16BR/YL 2 FUEL INJECTOR 1 LOW-SIDE CONTROL K611 16BR/RD Component Location - 20 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 3772 Connector: Name : INJECTOR-FUEL 1 Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 INJECTOR 1 CONTROL K11 20YL/BR 2 FUSED MAIN RELAY OUTPUT K343 16BR/YL Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 3773 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 3774 Fuel Injector: Locations Injector-Fuel 2 Component ID: 111 Component : INJECTOR-FUEL 2 Connector: Name : INJECTOR-FUEL 2 Color : BLACK # of pins : 2 Qualifier : (DIESEL) Pin Description Circuit 1 FUEL INJECTOR HIGH-SIDE COMMON K663 16BR/YL 2 FUEL INJECTOR 2 LOW-SIDE CONTROL K612 16BR/LG Component Location - 20 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 3775 Connector: Name : INJECTOR-FUEL 2 Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 INJECTOR 2 CONTROL K12 20BR/DB 2 FUSED MAIN RELAY OUTPUT K343 16BR/YL Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 3776 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 3777 Fuel Injector: Locations Injector-Fuel 3 Component ID: 112 Component : INJECTOR-FUEL 3 Connector: Name : INJECTOR-FUEL 3 Color : BLACK # of pins : 2 Qualifier : (DIESEL) Pin Description Circuit 1 FUEL INJECTOR HIGH-SIDE COMMON K663 16BR/YL 2 FUEL INJECTOR 3 LOW-SIDE CONTROL K613 16BR/WT Component Location - 20 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 3778 Connector: Name : INJECTOR-FUEL 3 Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 INJECTOR 3 CONTROL K13 20BR/LB 2 FUSED MAIN RELAY OUTPUT K343 16BR/YL Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 3779 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 3780 Fuel Injector: Locations Injector-Fuel 4 Component ID: 113 Component : INJECTOR-FUEL 4 Connector: Name : INJECTOR-FUEL 4 Color : BLACK # of pins : 2 Qualifier : (DIESEL) Pin Description Circuit 1 FUEL INJECTOR HIGH-SIDE COMMON K663 16BR/YL 2 FUEL INJECTOR 4 LOW-SIDE CONTROL K614 16BR/LB Component Location - 20 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 3781 Connector: Name : INJECTOR-FUEL 4 Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 INJECTOR 4 CONTROL K14 20BR/TN 2 FUSED MAIN RELAY OUTPUT K343 16BR/YL Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 3782 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 Fuel Injector: Diagrams Injector-Fuel 1 Component ID: 110 Component : INJECTOR-FUEL 1 Connector: Name : INJECTOR-FUEL 1 Color : BLACK # of pins : 2 Qualifier : (DIESEL) Pin Description Circuit 1 FUEL INJECTOR HIGH-SIDE COMMON K663 16BR/YL 2 FUEL INJECTOR 1 LOW-SIDE CONTROL K611 16BR/RD Component Location - 20 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 3785 Connector: Name : INJECTOR-FUEL 1 Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 INJECTOR 1 CONTROL K11 20YL/BR 2 FUSED MAIN RELAY OUTPUT K343 16BR/YL Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 3786 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 3787 Fuel Injector: Diagrams Injector-Fuel 2 Component ID: 111 Component : INJECTOR-FUEL 2 Connector: Name : INJECTOR-FUEL 2 Color : BLACK # of pins : 2 Qualifier : (DIESEL) Pin Description Circuit 1 FUEL INJECTOR HIGH-SIDE COMMON K663 16BR/YL 2 FUEL INJECTOR 2 LOW-SIDE CONTROL K612 16BR/LG Component Location - 20 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 3788 Connector: Name : INJECTOR-FUEL 2 Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 INJECTOR 2 CONTROL K12 20BR/DB 2 FUSED MAIN RELAY OUTPUT K343 16BR/YL Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 3789 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 3790 Fuel Injector: Diagrams Injector-Fuel 3 Component ID: 112 Component : INJECTOR-FUEL 3 Connector: Name : INJECTOR-FUEL 3 Color : BLACK # of pins : 2 Qualifier : (DIESEL) Pin Description Circuit 1 FUEL INJECTOR HIGH-SIDE COMMON K663 16BR/YL 2 FUEL INJECTOR 3 LOW-SIDE CONTROL K613 16BR/WT Component Location - 20 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 3791 Connector: Name : INJECTOR-FUEL 3 Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 INJECTOR 3 CONTROL K13 20BR/LB 2 FUSED MAIN RELAY OUTPUT K343 16BR/YL Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 3792 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 3793 Fuel Injector: Diagrams Injector-Fuel 4 Component ID: 113 Component : INJECTOR-FUEL 4 Connector: Name : INJECTOR-FUEL 4 Color : BLACK # of pins : 2 Qualifier : (DIESEL) Pin Description Circuit 1 FUEL INJECTOR HIGH-SIDE COMMON K663 16BR/YL 2 FUEL INJECTOR 4 LOW-SIDE CONTROL K614 16BR/LB Component Location - 20 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 3794 Connector: Name : INJECTOR-FUEL 4 Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 INJECTOR 4 CONTROL K14 20BR/TN 2 FUSED MAIN RELAY OUTPUT K343 16BR/YL Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 3795 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Description and Operation > Description Fuel Injector: Description and Operation Description DESCRIPTION The injectors are positioned in the intake manifold with the nozzle ends directly above the intake valve port. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Description and Operation > Description > Page 3798 Fuel Injector: Description and Operation Operation OPERATION The fuel injectors are 12 volt electrical solenoids. The injector contains a pintle that closes off an orifice at the nozzle end. When electric current is supplied to the injector, the armature and needle move a short distance against a spring, allowing fuel to flow out the orifice. Because the fuel is under high pressure, a fine spray is developed in the shape of a hollow cone or two streams. The spraying action atomizes the fuel, adding it to the air entering the combustion chamber. Fuel injectors are not interchangeable between engines. Injector operation is controlled by a ground path provided for each injector by the PCM. Injector on-time (pulse-width) is variable, and is determined by the PCM processing all the data previously discussed to obtain the optimum injector pulse width for each operating condition. The pulse width is controlled by the duration of the ground path provided. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Removal - Injector Connector Fuel Injector: Service and Repair Removal - Injector Connector REMOVAL - INJECTOR CONNECTOR 1. Disconnect electrical connectors at the fuel injectors. 2. To remove connector pull the red colored slider away from injector (1). While pulling the slider, depress tab (2) and remove connector (3) from injector. The factory fuel injection wiring harness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification. If harness is not tagged, make note of wiring location before removal. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Removal - Injector Connector > Page 3801 Fuel Injector: Service and Repair Removal 2.0/2.4L WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the vehicle. This may result in personal injury or death. 1. Release the fuel pressure. 2. Disconnect the negative battery cable. 3. Disconnect the electrical connectors from the fuel injectors. 4. Fuel line connection at fuel rail. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Removal - Injector Connector > Page 3802 5. Remove the fuel line from the fuel rail. 6. Remove wire harness from fuel rail mounting studs. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Removal - Injector Connector > Page 3803 7. Remove the 2 bolts to the fuel rail at the lower manifold. 8. Remove the fuel rail. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Removal - Injector Connector > Page 3804 9. Remove clip holding fuel injector to fuel rail. 10. Remove fuel injector clip and fuel injector from fuel rail. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Removal - Injector Connector > Page 3805 Fuel Injector: Service and Repair Installation 2.0/2.4L 1. Apply a light coating of clean engine oil to the upper O-ring. 2. Install injector in cup on fuel rail. 3. Install retaining clip. 4. Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector. 5. Insert fuel injector nozzles into openings in lower intake manifold. Seat the injectors in place. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Removal - Injector Connector > Page 3806 6. Tighten fuel rail mounting screws to 27 Nm (20 ft. lbs.). 7. Install wiring harness clips to the fuel rail mounting studs. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Removal - Injector Connector > Page 3807 8. Attach electrical connectors to fuel injectors. 9. Connect fuel supply tube to fuel rail. 10. Connect the negative battery cable. 11. Use the scan tool to pressurize the fuel system. Check for leaks. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair Fuel Line Coupler: Service and Repair STANDARD PROCEDURE - QUICK-CONNECT FITTINGS TWO-TAB IN WINDOW TYPE FITTING When disconnecting a quick-connect fitting, the retainer will remain on the fuel tube nipple. WARNING: Release fuel system pressure before disconnecting a quick-connect fittings. This may result in personal injury or death. 1. Perform Fuel Pressure Release Procedure. 2. Disconnect negative cable from battery or auxiliary jumper terminal. 3. Squeeze retainer tabs (2) together and pull fuel tube/quick-connect fitting assembly off of fuel tube nipple. CAUTION: Make sure that the O-ring in installed in fitting. Never install a quick-connect fitting without the retainer being either on the fuel tube or already in the quick-connect fitting. In either case, ensure the retainer locks securely into the quick-connect fitting by firmly push-pulling-push on fuel tube and fitting to ensure it is secured. 4. Using a clean lint free cloth, clean the fuel tube nipple and retainer. 5. Prior to connecting the fitting to the fuel tube, coat the fuel tube nipple with clean engine oil. 6. Push the quick-connect fitting over the fuel tube until the retainer seats and a click is heard. 7. The plastic quick-connect fitting has windows in the sides of the casing. When the fitting completely attaches to the fuel tube, the retainer locking ears (2) and the fuel tube shoulder are visible in the windows (1). If they are not visible, the retainer was not properly installed. Do not rely upon the audible click to confirm a secure connection. 8. Connect negative cable to battery or auxiliary jumper terminal. 9. Use the scan tool Fuel System Test to pressurize the fuel system. Check for leaks. TWO-TAB TYPE FITTING Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Page 3811 This type of fitting is equipped with tabs located on both sides of the fitting. These tabs are supplied for disconnecting the quick-connect fitting from component being serviced. CAUTION: The interior components (O-rings, spacers) of this type of quick-connect fitting are not serviced separately, but new plastic retainers are available. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly. WARNING: The fuel system is under a constant pressure (even with the engine off). Before servicing any fuel system hoses, fittings or lines, the fuel system pressure must be released. Refer to the fuel pressure release procedure. This may result in personal injury or death. DISCONNECTION/CONNECTION 1. Perform fuel pressure release procedure. 2. Disconnect negative battery cable from battery or auxiliary jumper terminal. 3. Clean fitting of any foreign material before disassembly. 4. To disconnect quick-connect fitting, squeeze plastic retainer tabs (1) against sides of quick-connect fitting with your fingers. Tool use is not required for removal and may damage plastic retainer. Pull fitting from fuel system component being serviced. The plastic retainer will remain on component being serviced after fitting is disconnected. The O-rings and spacer will remain in quick-connect fitting connector body. 5. Inspect quick-connect fitting body and component for damage. Replace as necessary. CAUTION: When the quick-connect fitting was disconnected, the plastic retainer will remain on the component being serviced. If this retainer must be removed, very carefully release the retainer from the component with two small screwdrivers. After removal, inspect the retainer for cracks or any damage. 6. Prior to connecting quick-connect fitting to component being serviced, check condition of fitting and component. Clean parts with a lint-free cloth. Lubricate with clean engine oil. 7. Insert quick-connect fitting to component being serviced and into plastic retainer. When a connection is made, a click will be heard. 8. Verify a locked condition by firmly push-pulling-push on fuel tube and fitting (15-30 lbs.). 9. Connect negative cable to battery or auxiliary jumper terminal. 10. Use the scan tool Fuel System Test to pressurize the fuel system. Check for leaks. PLASTIC RETAINER RING TYPE FITTING Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Page 3812 This type of fitting can be identified by the use of a full-round plastic retainer ring usually black in color. CAUTION: The interior components (O-rings, spacers, retainers) of this type of quick-connect fitting are not serviced separately. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly. WARNING: The fuel system is under a constant pressure (even with the engine off). Before servicing any fuel system hoses, fittings or lines, the fuel system pressure must be released. Refer to the fuel system pressure release procedure. This may result in personal injury or death. DISCONNECTION/CONNECTION 1. Perform fuel pressure release procedure. 2. Disconnect negative battery cable from battery or auxiliary jumper terminal. 3. Clean fitting of any foreign material before disassembly. 4. To release fuel system component from quick-connect fitting, firmly push fitting towards component being serviced while firmly pushing plastic retainer ring into fitting. With plastic ring depressed, pull fitting from component. The plastic retainer ring must be pressed squarely into fitting body. If this retainer is cocked during removal, it may be difficult to disconnect fitting. Use an open-end wrench on shoulder of plastic retainer ring to aid in disconnection. 5. After disconnection, plastic retainer ring will remain with quick-connect fitting connector body. 6. Inspect fitting connector body, plastic retainer ring and fuel system component for damage. Replace as necessary. 7. Prior to connecting quick-connect fitting to component being serviced, check condition of fitting and component. Clean parts with a lint-free cloth. Lubricate with clean engine oil. 8. Insert quick-connect fitting into component being serviced until a click is felt. 9. Verify a locked condition by firmly push-pulling-push on fuel tube and fitting (15-30 lbs.). 10. Connect negative battery cable to battery or auxiliary jumper terminal. 11. Use the scan tool Fuel System Test to pressurize the fuel system. Check for leaks. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL SYSTEM PRESSURE Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 3817 Fuel Pressure: Testing and Inspection *CHECKING THE FUEL DELIVERY SYSTEM For a complete wiring diagram refer to Diagrams/Electrical. Diagnostic Test 1. CHECKING THE FUEL PUMP OPERATION Turn the ignition on. NOTE: Diagnose and repair any fuel pump control circuit or relay DTCs before continuing with this test. With a scan tool, actuate the fuel pump control to ON (100%). NOTE: It may be necessary to use a mechanics stethoscope in the next step. Listen for fuel pump operation at the fuel tank. The fuel pump should operate smoothly, without excessive noise. If necessary, compare to a known good vehicle of similar year, make, and model. NOTE: If the pump has excessive noise or grinding, the pump should be replaced. caution: Stop all actuation tests before continuing. Is the fuel pump operating when actuated? Yes - Go to 2 No - Go to 7 2. CHECKING THE FUEL PRESSURE Turn the ignition off. WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in personal injury or death. Install a fuel pressure gauge on the fuel rail. Turn the ignition on. With the scan tool, actuate the fuel pump relay control. Observe the fuel pressure gauge. NOTE: The fuel pressure specification is 407 KPa ± 34 KPa (59 psi ± 5 psi). caution: Stop all actuation tests before continuing. Select the conclusion that best matches the result of the test: Fuel pressure is within the stated specification - Test complete. Fuel pressure is below the stated specification - Go to 3 Fuel pressure is above the stated specification - Replace the fuel filter/pressure regulator. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 3818 - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 3. RESTRICTED FUEL SUPPLY LINE Turn the ignition off. WARNING: The fuel system is under a constant pressure, even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in personal injury or death. Raise vehicle on hoist, and disconnect the fuel pressure line at the fuel pump module. Install special 5/16 fuel line adapter tool #6539 between disconnected fuel line and the fuel pump module. Attach a fuel pressure test gauge to the T fitting on tool #6539. Turn the ignition on. With the scan tool, actuate the fuel pump relay control. Observe the fuel pressure gauge. NOTE: Fuel pressure specification is 407 KPa ± 34 KPa (59 psi ± 5 psi). caution: Stop all actuation tests before proceeding. Is the fuel pressure within specification? Yes - Repair or replace fuel supply line as necessary. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 4 4. SADDLE FUEL TANK Is the vehicle equipped with a saddle type fuel tank? Yes - Go to 5 No - Go to 6 5. FUEL TANK SIPHON HOSE OR FUEL LINE RESTRICTED OR DAMAGED Turn the ignition off. WARNING: The fuel system is under a constant pressure, even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in personal injury or death. Gain access to the fuel pump module and the fuel tank module. Inspect the fuel line and siphon hose between the fuel pump module and the fuel tank module. Look for disconnected or damaged lines and hoses. Inspect the fuel pressure regulator for damage or a condition that might cause a fuel flow problem. Make sure that it is seated in the module properly. Were any problems found? Yes - Repair as necessary. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 3819 - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 6 6. FUEL PUMP INLET STRAINER Turn the ignition off. WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in personal injury or death. Remove the fuel pump module and inspect the fuel inlet strainer for damage or a condition that might cause a fuel flow problem. Were any problems found? Yes - Replace the Fuel Pump Inlet Strainer. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Replace the Fuel Pump Module. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 7. FUEL PUMP GROUND CIRCUIT OPEN OR HIGH RESISTANCE Turn the ignition off. Disconnect the Fuel Pump Module harness connector. Using a 12 volt test light connected to 12 volts, check the Fuel Pump Motor Ground circuit at the Fuel Pump Module harness connector. NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated and bright? Yes - Replace the Fuel Pump Module. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Repair the Fuel Pump Ground circuit for an open circuit or high resistance. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Description and Operation Fuel Pump Pickup Filter: Description and Operation DESCRIPTION The fuel pump inlet strainer is a non-serviceable part. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Description Fuel Rail: Description and Operation Description DESCRIPTION The fuel rail supplies the necessary fuel to each individual fuel injector and is mounted to the intake manifold. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Description > Page 3827 Fuel Rail: Description and Operation Operation OPERATION The fuel pressure regulator is no longer mounted to the fuel rail on any engine. It is now located on the fuel tank mounted fuel pump module. The fuel rail is not repairable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Removal Fuel Rail: Service and Repair Removal 2.0/2.4L WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the vehicle. This may result in personal injury or death. NOTE: Wrap shop towels around hose to catch any gasoline spillage. 1. Release the fuel system pressure. 2. Disconnect the negative battery cable. 3. Disconnect the fuel line from the fuel rail. 4. Fuel line removed from the fuel rail. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Removal > Page 3830 5. Unlock and disconnect the electrical connectors from the fuel injectors. 6. Remove the wiring harness from the fuel rail studs. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Removal > Page 3831 7. Remove the 2 bolts from the fuel rail. 8. Remove the fuel rail and injectors from the intake manifold. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Removal > Page 3832 9. Fuel rail removed from intake manifold. 10. Remove fuel injectors from fuel rail. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Removal > Page 3833 Fuel Rail: Service and Repair Installation 2.0/2.4L 1. Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector. 2. Install the fuel injectors to the fuel rail. 3. Install injector into cup of fuel rail. 4. Install retaining clip and check to ensure injector is properly captured. Fuel rail assembly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Removal > Page 3834 5. Insert fuel injector nozzles into openings in intake manifold. Seat the injectors in place. 6. Install the 2 bolts to the fuel rail. Tighten fuel rail bolts to 27 Nm (20 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Removal > Page 3835 7. Install the wiring harness to the fuel rail. 8. Connect and lock the electrical connectors to the fuel injectors. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Removal > Page 3836 9. Connect the fuel line to the fuel rail. 10. Connect the negative battery cable. 11. Use the Scan Tool Fuel System Test to pressurize the fuel system. Check for leaks. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Description and Operation Fuel Return Line: Description and Operation DESCRIPTION - FUEL LINES/HOSES AND CLAMPS Also refer to Quick-Connect Fittings. WARNING: The fuel system is under a constant pressure (even with the engine off). Before servicing any fuel system hoses, fittings or lines, the fuel system pressure must be released. Refer to the fuel system pressure release procedure. This may result in personal injury or death. The lines/tubes/hoses used on fuel injected vehicles are of a special construction. This is due to the higher fuel pressures and the possibility of contaminated fuel in this system. If it is necessary to replace these lines/tubes/hoses, use new original equipment lines/tubes/hoses. If equipped: The hose clamps used to secure rubber hoses on vehicles are of a special rolled edge construction. This construction is used to prevent the edge of the clamp from cutting into the hose. Only these rolled edge type clamps may be used in this system. All other types of clamps may cut into the hoses and cause leaks. Use new original equipment type hose clamps. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Description and Operation > Page 3840 Fuel Return Line: Service and Repair STANDARD PROCEDURE - HOSES AND CLAMP Inspect all hose connections (clamps and quick connect fittings) for completeness and leaks. Replace cracked, scuffed, or swelled hoses. Replace hoses that rub against other vehicle components or show sign of wear. Fuel injected vehicles use specially constructed hoses. When replacing hoses, only use hoses marked EFM/EFI. When installing hoses, ensure that they are routed away from contact with other vehicle components that could rub against them and cause failure. Avoid contact with clamps or other components that cause abrasions or scuffing. Ensure that rubber hoses are properly routed and avoid heat sources. The hose clamps have rolled edges to prevent the clamp from cutting into the hose. Only use clamps that are original equipment or equivalent. Other types of clamps may cut into the hoses and cause high pressure fuel leaks. Tighten hose clamps to 1 Nm (9 in. lbs.). Inspect all hose connections such as clamps, couplings and fittings to make sure they are secure and leaks are not present. The component should be replaced immediately if there is any evidence of degradation that could result in failure. Never attempt to repair a plastic fuel line/tube. Replace as necessary. Avoid contact of any fuel tubes/hoses with other vehicle components that could cause abrasions or scuffing. Be sure that the plastic fuel lines/tubes are properly routed to prevent pinching and to avoid heat sources. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation Fuel Supply Line: Description and Operation DESCRIPTION - FUEL LINES/HOSES AND CLAMPS Also refer to Quick-Connect Fittings. WARNING: The fuel system is under a constant pressure (even with the engine off). Before servicing any fuel system hoses, fittings or lines, the fuel system pressure must be released. Refer to the fuel system pressure release procedure. This may result in personal injury or death. The lines/tubes/hoses used on fuel injected vehicles are of a special construction. This is due to the higher fuel pressures and the possibility of contaminated fuel in this system. If it is necessary to replace these lines/tubes/hoses, use new original equipment lines/tubes/hoses. If equipped: The hose clamps used to secure rubber hoses on vehicles are of a special rolled edge construction. This construction is used to prevent the edge of the clamp from cutting into the hose. Only these rolled edge type clamps may be used in this system. All other types of clamps may cut into the hoses and cause leaks. Use new original equipment type hose clamps. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation > Page 3844 Fuel Supply Line: Service and Repair STANDARD PROCEDURE - HOSES AND CLAMP Inspect all hose connections (clamps and quick connect fittings) for completeness and leaks. Replace cracked, scuffed, or swelled hoses. Replace hoses that rub against other vehicle components or show sign of wear. Fuel injected vehicles use specially constructed hoses. When replacing hoses, only use hoses marked EFM/EFI. When installing hoses, ensure that they are routed away from contact with other vehicle components that could rub against them and cause failure. Avoid contact with clamps or other components that cause abrasions or scuffing. Ensure that rubber hoses are properly routed and avoid heat sources. The hose clamps have rolled edges to prevent the clamp from cutting into the hose. Only use clamps that are original equipment or equivalent. Other types of clamps may cut into the hoses and cause high pressure fuel leaks. Tighten hose clamps to 1 Nm (9 in. lbs.). Inspect all hose connections such as clamps, couplings and fittings to make sure they are secure and leaks are not present. The component should be replaced immediately if there is any evidence of degradation that could result in failure. Never attempt to repair a plastic fuel line/tube. Replace as necessary. Avoid contact of any fuel tubes/hoses with other vehicle components that could cause abrasions or scuffing. Be sure that the plastic fuel lines/tubes are properly routed to prevent pinching and to avoid heat sources. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 14-003-07 > May > 07 > Body - Fuel Filler Door Under Flush Fuel Filler Neck: Customer Interest Body - Fuel Filler Door Under Flush NUMBER: 14-003-07 GROUP: Fuel System DATE: May 31, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-006-06, DATED AUGUST 16, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF MODELS, REPAIR PROCEDURE STEPS AND PARTS. SUBJECT: Under Flush Fuel Filler Door Splash Shield OVERVIEW: This bulletin involves installing a Fuel Filler Neck Spacer. MODELS: 2007 (PM) Caliber 2007 (MK-49) Compass **2007 (MK74) Patriot** NOTE: This bulletin applies to PM and MK-49 models built before June 22, 2006 (MDH 0622XX) **and MK74 models built prior to April 3, 2007 (MDH 0403xx)**. SYMPTOM/CONDITION: The condition may present itself as a under-flush fuel filler door or loose fuel filler neck which may be more noticeable when the vehicle is being fueled up. This condition can also be described as a loose fuel filler neck housing. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open the fuel door. 2. Pull the fuel filler housing back into place. It may be necessary to remove the splash shield to secure housing. All clips must be engaged. 3. **Refer to proper step based on vehicle being serviced: a. PM - Caliber or MK49 - Compass, go to > next step. b. MK74 - Patriot, go to > Step # 5** Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 14-003-07 > May > 07 > Body - Fuel Filler Door Under Flush > Page 3854 4. PM/MK49: Install the fuel filler neck spacer over the lower screw (Fig 1). NOTE: Be sure to orient the spacer correctly before installing. 5. **MK74: Install the fuel filler neck spacer over the lower screw on fuel door mount. Push spacer all the way in until it clicks** (Fig 2) POLICY: Reimbursable within the provisions of the warranty. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 14-003-07 > May > 07 > Body - Fuel Filler Door Under Flush > Page 3855 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 14-003-07 > May > 07 > Body - Fuel Filler Door Under Flush Fuel Filler Neck: All Technical Service Bulletins Body - Fuel Filler Door Under Flush NUMBER: 14-003-07 GROUP: Fuel System DATE: May 31, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-006-06, DATED AUGUST 16, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF MODELS, REPAIR PROCEDURE STEPS AND PARTS. SUBJECT: Under Flush Fuel Filler Door Splash Shield OVERVIEW: This bulletin involves installing a Fuel Filler Neck Spacer. MODELS: 2007 (PM) Caliber 2007 (MK-49) Compass **2007 (MK74) Patriot** NOTE: This bulletin applies to PM and MK-49 models built before June 22, 2006 (MDH 0622XX) **and MK74 models built prior to April 3, 2007 (MDH 0403xx)**. SYMPTOM/CONDITION: The condition may present itself as a under-flush fuel filler door or loose fuel filler neck which may be more noticeable when the vehicle is being fueled up. This condition can also be described as a loose fuel filler neck housing. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open the fuel door. 2. Pull the fuel filler housing back into place. It may be necessary to remove the splash shield to secure housing. All clips must be engaged. 3. **Refer to proper step based on vehicle being serviced: a. PM - Caliber or MK49 - Compass, go to > next step. b. MK74 - Patriot, go to > Step # 5** Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 14-003-07 > May > 07 > Body - Fuel Filler Door Under Flush > Page 3861 4. PM/MK49: Install the fuel filler neck spacer over the lower screw (Fig 1). NOTE: Be sure to orient the spacer correctly before installing. 5. **MK74: Install the fuel filler neck spacer over the lower screw on fuel door mount. Push spacer all the way in until it clicks** (Fig 2) POLICY: Reimbursable within the provisions of the warranty. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 14-003-07 > May > 07 > Body - Fuel Filler Door Under Flush > Page 3862 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Service and Repair > Removal Fuel Filler Neck: Service and Repair Removal REMOVAL NOTE: Drain fuel tank if it is more than half full. 1. Remove the negative battery cable. 2. Loosen fuel filler tube cap. 3. Raise vehicle and support. 4. Remove the left rear wheel. 5. Remove the inner splash shield. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Service and Repair > Removal > Page 3865 6. Disconnect filler tube recirculation vent line. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Service and Repair > Removal > Page 3866 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Service and Repair > Removal > Page 3867 Fuel Filler Neck: Service and Repair Installation INSTALLATION 1. Install fuel filler tube. Connect fuel filler tube hose to fuel tank neck and tighten clamp to 2.8 Nm (24 in. lbs.). 2. Install fuel filler tube mounting screw and tighten to 9 Nm (79.5 in. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Service and Repair > Removal > Page 3868 3. Connect filler tube vent line. 4. Install the inner splash shield. 5. Install rear tire. 6. Lower vehicle. 7. Install fuel filler tube cap. 8. Install the negative battery cable. 9. Install the air cleaner lid and makeup air hose. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Service and Repair > Removal Fuel Tank Unit: Service and Repair Removal All Wheel Drive ALL WHEEL DRIVE WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the vehicle. This may result in personal injury or death. 1. Perform Fuel System Pressure Release procedure. 2. Remove the air cleaner lid, disconnect the inlet air temperature sensor and makeup air hose. 3. Remove the negative battery cable. 4. Remove the rear seat cushion. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Service and Repair > Removal > Page 3873 5. Rear seat cushion loose. 6. Remove plastic cover. 7. Clean top of tank to remove loose dirt and debris. 8. Use special tool Spanner Wrench #9340 to remove left side module lock ring. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Service and Repair > Removal > Page 3874 9. Note the fuel pump location on the top of the fuel tank. NOTE: The pump has to be properly located to the tank for the fuel gauge to work properly. 10. Pull module up out of fuel tank, make sure that you do not spill fuel inside of vehicle. 11. Drain fuel from fuel pump module. Do not spill fuel in interior of vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Service and Repair > Removal > Page 3875 12. Disconnect internal line from fuel pump module. 13. Tip module on its side to drain remaining fuel from reservoir and remove module from vehicle. 14. Remove module from vehicle. 15. Remove seal from tank. Discard seal. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Service and Repair > Removal > Page 3876 16. Remove plastic cover. 17. Clean top of tank to remove loose dirt and debris. 18. Disconnect electrical line from module. 19. Note the fuel level unit location on the top of the fuel tank (1). NOTE: The fuel level unit has to be properly located to the tank for the fuel gauge to work properly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Service and Repair > Removal > Page 3877 20. Using Special Tool Lock Ring #9318 remove lock ring (2) to release fuel level unit. 21. Note the fuel level unit location on the top of the fuel tank. NOTE: The fuel level unit has to be properly located to the tank for the fuel gauge to work properly. 22. Remove fuel level unit module and disconnect line. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Service and Repair > Removal > Page 3878 23. Remove module and seal from tank. Discard seal. Front Wheel Drive FRONT WHEEL DRIVE WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the vehicle. This may result in personal injury or death. 1. Perform Fuel System Pressure Release procedure. 2. Remove the air cleaner lid, disconnect the inlet air temperature sensor and makeup air hose. 3. Remove the negative battery cable. 4. Remove the rear seat cushion. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Service and Repair > Removal > Page 3879 5. Rear seat cushion loose. 6. Remove plastic cover. 7. Clean top of tank to remove loose dirt and debris. 8. Use special tool #9340 to remove left side module lock ring. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Service and Repair > Removal > Page 3880 9. Note the fuel pump location on the top of the fuel tank. NOTE: The pump has to be properly located to the tank for the fuel gauge to work properly. 10. Pull module up out of fuel tank, make sure that you do not spill fuel inside of vehicle. 11. Drain fuel from fuel pump module. Do not spill fuel in interior of vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Service and Repair > Removal > Page 3881 Fuel Tank Unit: Service and Repair Installation All Wheel Drive ALL WHEEL DRIVE NOTE: The pump has to be properly located to the tank for the fuel gauge to work properly. 1. Wipe seal area of tank clean. Place a new seal between the tank threads and the pump module opening. 2. Connect line to module. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Service and Repair > Removal > Page 3882 3. Install module. 4. Position fuel pump module in tank. Make sure the alignment tab lines up on the fuel tank and pump module for Gas or Diesel fuel tanks. 5. While holding the pump module in position, install lock ring and use special tool Lock Ring #9340 to tighten lock ring. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Service and Repair > Removal > Page 3883 6. Install plastic cover. 7. Wipe seal area of tank clean. Place a new seal between the tank threads and the pump module opening. 8. Connect line and install venturi module. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Service and Repair > Removal > Page 3884 9. Position fuel pump module in tank. Make sure the alignment tab line up on the fuel tank and pump module for Gas or Diesel fuel tanks. 10. While holding the pump module in position, install lock ring and use special tool Spanner Wrench #9340 to tighten lock ring. 11. Connect electrical connector. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Service and Repair > Removal > Page 3885 12. Install plastic cover. 13. Install rear cushion. 14. Install the negative battery cable. 15. Install the air cleaner lid, connect the inlet air temperature sensor and makeup air hose. 16. Fill fuel tank with clean fuel. Use the Scan Tool to pressurize the system and check for leaks. Front Wheel Drive FRONT WHEEL DRIVE NOTE: The pump has to be properly located to the tank for the fuel gauge to work properly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Service and Repair > Removal > Page 3886 1. Wipe seal area of tank clean. Place a new seal between the tank threads and the pump module opening. 2. Install module. 3. Position fuel pump module in tank. Make sure the alignment tab lines up on the fuel tank and pump module for Gas or Diesel fuel tanks. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Service and Repair > Removal > Page 3887 4. While holding the pump module in position, install lock ring and use special tool Spanner Wrench #9340 to tighten lock ring. 5. Install plastic cover. 6. Install rear cushion. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Service and Repair > Removal > Page 3888 7. Install the negative battery cable. 8. Install the air cleaner lid, connect the inlet air temperature sensor and makeup air hose. 9. Fill fuel tank with clean fuel. Use the Scan Tool to pressurize the system and check for leaks. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Main Relay is located in the Fuse/Relay block. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3892 Main Relay (Computer/Fuel System): Diagrams Component ID: 182 Component : RELAY-MAIN Connector: Name : RELAY-MAIN Color : # of pins : 0 B6 FUSED B(+) A14 12RD/YL B7 MAIN RELAY OUTPUT K542 12BR/WT B8 - B9 FUSED B(+) A14 12RD/YL B10 MAIN RELAY CONTROL K51 20BR/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Main Relay is located in the Fuse/Relay block. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3897 Main Relay (Computer/Fuel System): Diagrams Component ID: 182 Component : RELAY-MAIN Connector: Name : RELAY-MAIN Color : # of pins : 0 B6 FUSED B(+) A14 12RD/YL B7 MAIN RELAY OUTPUT K542 12BR/WT B8 - B9 FUSED B(+) A14 12RD/YL B10 MAIN RELAY CONTROL K51 20BR/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Component ID: 281 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 APP SIGNAL 2 K29 20WT/BR 2 APP SENSOR GROUND 2 K400 20BR/VT 3 5 VOLT SUPPLY K854 20VT/BR 3 5 VOLT SUPPLY K858 20BR/GY 4 APP SIGNAL 1 K23 20BR/OR 5 APP SENSOR GROUND 1 K167 20BR/YL 6 5 VOLT SUPPLY K852 20BR/VT 6 5 VOLT SUPPLY F856 20YL/PK Component Location - 44 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3902 Component Location - 47 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3903 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3904 Accelerator Pedal Position Sensor: Diagrams Component ID: 281 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 APP SIGNAL 2 K29 20WT/BR 2 APP SENSOR GROUND 2 K400 20BR/VT 3 5 VOLT SUPPLY K854 20VT/BR 3 5 VOLT SUPPLY K858 20BR/GY 4 APP SIGNAL 1 K23 20BR/OR 5 APP SENSOR GROUND 1 K167 20BR/YL 6 5 VOLT SUPPLY K852 20BR/VT 6 5 VOLT SUPPLY F856 20YL/PK Component Location - 44 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3905 Component Location - 47 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3906 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3907 Accelerator Pedal Position Sensor: Description and Operation DESCRIPTION The Accelerator Pedal Position Sensor (APPS) is a variable resistor that provides the PCM with an input signal (voltage). The signal represents pedal angle position. As the position of the accelerator pedal changes, the resistance of the APPS changes. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal Accelerator Pedal Position Sensor: Service and Repair Removal REMOVAL 1. Disconnect negative battery cable. 2. Disconnect the electrical connector from the module. 3. Remove the mounting nuts. 4. Remove assembly from the mounting studs. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal > Page 3910 Accelerator Pedal Position Sensor: Service and Repair Installation INSTALLATION 1. Install APPS module. 2. Tighten the mounting nuts. 3. Connect electrical connector. 4. Connect negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Description and Operation Turbo Boost Sensor: Description and Operation DESCRIPTION Turbocharged vehicles are equipped with three solenoids that are PCM controlled. They are mounted to the right shock tower. A vacuum harness connects the solenoids to their respective component. - Wastegate Actuator Solenoid - Surge Valve Actuator Solenoid - Throttle Inlet Pressure (TIP) Solenoid Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Service and Repair > Removal Turbo Boost Sensor: Service and Repair Removal REMOVAL 1. Remove nuts (1) securing solenoid mounting bracket to shock tower. 2. Disconnect solenoid electrical connector. 3. Disconnect vacuum harness connector from solenoid. 4. Push on solenoid lock tab (1) and slide solenoid off bracket. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Service and Repair > Removal > Page 3916 Turbo Boost Sensor: Service and Repair Installation INSTALLATION 1. Slide solenoid onto mounting bracket until lock tab engages. 2. Connect vacuum harness connector to solenoid. 3. Connect solenoid electrical connector. 4. Install nuts securing solenoid mounting bracket to shock tower. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations Throttle Body: Locations Component ID: 359 Component : THROTTLE BODY Connector: Name : THROTTLE BODY Color : BLACK # of pins : 6 Qualifier : (GAS) Pin Description Circuit 1 ETC MOTOR (+) K124 20DB/GY 2 TP SENSOR GROUND K922 20BR 3 5 VOLT SUPPLY F855 20PK/YL 4 ETC MOTOR (-) K126 20DB/LG 5 TP SIGNAL 1 K22 20OR/BR 6 TP SIGNAL 2 K122 20DG/BR Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 3920 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 3921 Throttle Body: Diagrams Component ID: 359 Component : THROTTLE BODY Connector: Name : THROTTLE BODY Color : BLACK # of pins : 6 Qualifier : (GAS) Pin Description Circuit 1 ETC MOTOR (+) K124 20DB/GY 2 TP SENSOR GROUND K922 20BR 3 5 VOLT SUPPLY F855 20PK/YL 4 ETC MOTOR (-) K126 20DB/LG 5 TP SIGNAL 1 K22 20OR/BR 6 TP SIGNAL 2 K122 20DG/BR Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 3922 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Description and Operation > Description Throttle Body: Description and Operation Description DESCRIPTION The throttle body mounts to the intake manifold. The throttle position sensor and throttle actuating DC motor are integral to the throttle body. The throttle body is a non serviceable item, replace the throttle body as an assembly. The throttle blade will not close completely when engine is shut down. This engine off blade position is for start up. The electric throttle body will adjust the throttle blade for idle control as the idle air control valve adjusted idle speed previously on cable actuated throttle bodies. The electric throttle body will also adjust the throttle blade for normal driving operation. The throttle blade will move to the engine off blade position if throttle body codes are set to provide air for limp-in mode. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Description and Operation > Description > Page 3925 Throttle Body: Description and Operation Operation OPERATION Filtered air from the air cleaner enters the intake manifold through the throttle body. A throttle valve (plate) is used to supply air for all conditions from idle to wide open throttle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Removal Throttle Body: Service and Repair Removal 2.0/2.4L 1. Remove the engine cover. 2. Remove the negative battery cable. 3. Remove the air cleaner lid, disconnect the inlet air temperature sensor and makeup air hose. 4. Disconnect inlet hose from throttle body. 5. Remove wire harness clip from air tube. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Removal > Page 3928 6. Remove the electrical connector from the throttle body. 7. Remove throttle body support bracket and bolts. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Removal > Page 3929 8. Bracket removed and bolts. 9. Remove throttle body mounting bolts. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Removal > Page 3930 10. Throttle body O-ring (1) and location pins (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Removal > Page 3931 Throttle Body: Service and Repair Installation 2.0/2.4L 1. Make sure that the throttle body O-ring (1) is in place in the manifold. 2. Position throttle body on intake manifold alignment pins and install 2 mounting bolts. Do Not tighten bolts at this time. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Removal > Page 3932 3. Install throttle body bracket. 4. Tighten throttle body bolts in a cross pattern to 9 Nm (79.5 in. lbs.). 5. Throttle body bracket installed. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Removal > Page 3933 6. Connect electrical connector to throttle body. 7. Install air tube and connect wiring harness to air tube. 8. Connect negative battery cable. 9. A Scan Tool may be used to learn electrical parameters. Go to the Miscellaneous menu, and then select ETC Relearn. If the relearn is not preformed, a Diagnostic Trouble Code (DTC) will be set. If necessary, use a scan tool to erase any Diagnostic Trouble Codes (DTC's) from PCM. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Boost Solenoid, Turbocharger > Component Information > Description and Operation Boost Solenoid: Description and Operation DESCRIPTION Turbocharged vehicles are equipped with three solenoids that are PCM controlled. They are mounted to the right shock tower. A vacuum harness connects the solenoids to their respective component. - Wastegate Actuator Solenoid - Surge Valve Actuator Solenoid - Throttle Inlet Pressure (TIP) Solenoid Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Boost Solenoid, Turbocharger > Component Information > Service and Repair > Removal Boost Solenoid: Service and Repair Removal REMOVAL 1. Remove nuts (1) securing solenoid mounting bracket to shock tower. 2. Disconnect solenoid electrical connector. 3. Disconnect vacuum harness connector from solenoid. 4. Push on solenoid lock tab (1) and slide solenoid off bracket. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Boost Solenoid, Turbocharger > Component Information > Service and Repair > Removal > Page 3940 Boost Solenoid: Service and Repair Installation INSTALLATION 1. Slide solenoid onto mounting bracket until lock tab engages. 2. Connect vacuum harness connector to solenoid. 3. Connect solenoid electrical connector. 4. Install nuts securing solenoid mounting bracket to shock tower. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Intercooler Duct > Component Information > Service and Repair > Removal Intercooler Duct: Service and Repair Removal CHARGE AIR COOLER HOSES-REMOVAL HOSE - CHARGE AIR COOLER TO THROTTLE BODY 1. Remove air cleaner housing. 2. Disconnect negative battery cable. 3. Disconnect positive battery cable. 4. Remove battery and battery tray. 5. Remove battery tray support bracket. 6. Loosen hose clamp at charge air cooler (2). 7. Dislodge hose from charge air cooler. 8. Disconnect Inlet Air Temperature (IAT) sensor (2) connector. 9. Disconnect Throttle Inlet Pressure (TIP) hose from charge air cooler hose (1). 10. Loosen hose clamp at throttle body. 11. Remove charge air cooler hose. HOSE - TURBOCHARGER TO CHARGE AIR COOLER Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Intercooler Duct > Component Information > Service and Repair > Removal > Page 3946 1. Raise vehicle on hoist. 2. Loosen hose clamp at charge air cooler (1). 3. Dislodge hose from charge air cooler. 4. Loosen hose clamp at turbocharger. 5. Dislodge hose from turbocharger. 6. Remove nuts (3) securing charge air cooler hose to structural collar. 7. Remove charge air cooler hose. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Intercooler Duct > Component Information > Service and Repair > Removal > Page 3947 Intercooler Duct: Service and Repair Installation CHARGE AIR COOLER HOSES HOSE - CHARGE AIR COOLER TO THROTTLE BODY 1. Position hose to mounting location. 2. Connect hose to throttle body. 3. Connect hose to charge air cooler. 4. Tighten hose clamps to 1.7 Nm (15 in. lbs.). 5. Connect Throttle Inlet Pressure (TIP) hose to charge air cooler hose. 6. Connect Inlet Air Temperature (IAT) sensor connector. 7. Install battery tray support bracket. 8. Install battery tray and battery. 9. Connect positive battery cable. 10. Connect negative battery cable. 11. Install air cleaner housing. HOSE - TURBOCHARGER TO CHARGE AIR COOLER Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Intercooler Duct > Component Information > Service and Repair > Removal > Page 3948 1. Position hose to mounting location. 2. Temporarily install nuts securing charge air cooler hose to structural collar. 3. Connect hose to turbocharger. 4. Connect hose to charge air cooler. 5. Tighten hose clamps to 1.7 Nm (15 in. lbs.). 6. Tighten nuts securing charge air cooler hose to structural collar. 7. Lower vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbo Boost Sensor > Component Information > Description and Operation Turbo Boost Sensor: Description and Operation DESCRIPTION Turbocharged vehicles are equipped with three solenoids that are PCM controlled. They are mounted to the right shock tower. A vacuum harness connects the solenoids to their respective component. - Wastegate Actuator Solenoid - Surge Valve Actuator Solenoid - Throttle Inlet Pressure (TIP) Solenoid Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbo Boost Sensor > Component Information > Service and Repair > Removal Turbo Boost Sensor: Service and Repair Removal REMOVAL 1. Remove nuts (1) securing solenoid mounting bracket to shock tower. 2. Disconnect solenoid electrical connector. 3. Disconnect vacuum harness connector from solenoid. 4. Push on solenoid lock tab (1) and slide solenoid off bracket. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbo Boost Sensor > Component Information > Service and Repair > Removal > Page 3954 Turbo Boost Sensor: Service and Repair Installation INSTALLATION 1. Slide solenoid onto mounting bracket until lock tab engages. 2. Connect vacuum harness connector to solenoid. 3. Connect solenoid electrical connector. 4. Install nuts securing solenoid mounting bracket to shock tower. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbocharger Coolant Line > Component Information > Service and Repair > Removal - Lines And Hoses Turbocharger Coolant Line: Service and Repair Removal - Lines And Hoses REMOVAL - LINES AND HOSES COOLANT SUPPLY LINE 1. Raise vehicle on hoist. 2. Drain cooling system. 3. Remove banjo bolt from coolant supply line at turbocharger. 4. Disconnect coolant supply line flared fitting from brass fitting at engine block. 5. Remove coolant supply line. COOLANT RETURN LINE Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbocharger Coolant Line > Component Information > Service and Repair > Removal - Lines And Hoses > Page 3959 1. Drain cooling system. 2. Remove air cleaner housing. 3. Disconnect Inlet Air Temperature (IAT) sensor connector. 4. Disconnect Throttle Inlet Pressure (TIP) hose from charge air cooler hose. 5. Loosen hose clamp at throttle body. 6. Disconnect charge air cooler hose from throttle body. Reposition charge air cooler hose. 7. Remove fastener securing coolant return line bracket to cylinder head cover stud. 8. Remove hose clamp from coolant return line at heater tube. Disconnect hose from heater tube. 9. Remove banjo bolt from coolant return line at turbocharger. 10. Remove coolant return line. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbocharger Coolant Line > Component Information > Service and Repair > Removal - Lines And Hoses > Page 3960 Turbocharger Coolant Line: Service and Repair Installation INSTALLATION COOLANT SUPPLY LINE 1. If brass fitting was removed from engine block, apply thread sealer to threads and install in engine block. Tighten brass fitting to 41 Nm (30 ft. lbs.). 2. Position coolant supply line to mounting location. 3. Install NEW washers (2) on banjo fitting of coolant supply line. Hand start banjo bolt. 4. Hand start flared fitting of coolant supply line. 5. Tighten banjo fitting bolt to 37 Nm (27 ft. lbs.). 6. Tighten flared fitting to 31 Nm (23 ft. lbs.). 7. Lower vehicle. 8. Fill cooling system. COOLANT RETURN LINE 1. Position coolant return line to mounting location. 2. Install NEW washers (2) onto banjo fitting of coolant return line. Hand start banjo bolt. 3. Install hose onto heater tube. Install hose clamp. 4. Tighten banjo fitting bolt to 37 Nm (27 ft. lbs.). 5. Install fastener securing coolant return line bracket to cylinder head cover stud. 6. Connect charge air cooler hose to throttle body. 7. Tighten hose clamp to 1.7 Nm (15 in. lbs.). 8. Connect Throttle Inlet Pressure (TIP) hose to charge air cooler hose. 9. Connect Inlet Air Temperature (IAT) sensor connector. 10. Install air cleaner housing. 11. Fill cooling system. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Oil Line, Turbocharger > Component Information > Service and Repair > Removal - Lines And Hoses Oil Line: Service and Repair Removal - Lines And Hoses REMOVAL - LINES AND HOSES OIL SUPPLY LINE 1. Raise vehicle on hoist. 2. Remove elbow support bracket. 3. Disconnect oil supply line flared fitting from brass fitting at engine block. 4. Lower vehicle. 5. Disconnect oil supply line flared fitting from brass fitting at turbocharger. 6. Remove oil supply line. OIL RETURN LINE Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Oil Line, Turbocharger > Component Information > Service and Repair > Removal - Lines And Hoses > Page 3965 1. Raise vehicle on hoist. 2. Remove the two fasteners securing the oil return line to the turbocharger. 3. Remove hose clamp from oil return line. 4. Remove oil return line from crankcase nipple. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Oil Line, Turbocharger > Component Information > Service and Repair > Removal - Lines And Hoses > Page 3966 Oil Line: Service and Repair Installation INSTALLATION OIL SUPPLY LINE 1. If brass fitting was removed from engine block or turbocharger, apply thread sealer to threads and install. Tighten brass fitting to 41 Nm (30 ft. lbs.). 2. Position oil supply line to mounting location. 3. Hand start flared fitting at turbocharger. 4. Raise vehicle on hoist. 5. Hand start flared fitting at engine block. 6. Tighten flared fittings to 31 Nm (23 ft. lbs.). 7. Install elbow support bracket. 8. Lower vehicle. OIL RETURN LINE 1. Clean gasket surfaces. 2. Install new gasket. 3. Install oil return line hose over crankcase nipple. 4. Install the two fasteners securing the oil return line to the turbocharger. Tighten fasteners to 12 Nm (105 in. lbs.). 5. Install hose clamp for oil return line hose. 6. Lower vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Wastegate Solenoid > Component Information > Description and Operation > Wastegate Solenoid Wastegate Solenoid: Description and Operation Wastegate Solenoid DESCRIPTION The wastegate solenoid is used to send a vacuum signal which controls the wastegate actuator on the turbocharger. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Wastegate Solenoid > Component Information > Description and Operation > Wastegate Solenoid > Page 3971 Wastegate Solenoid: Description and Operation Solenoids And Vacuum Harness DESCRIPTION Turbocharged vehicles are equipped with three solenoids that are PCM controlled. They are mounted to the right shock tower. A vacuum harness connects the solenoids to their respective component. - Wastegate Actuator Solenoid - Surge Valve Actuator Solenoid - Throttle Inlet Pressure (TIP) Solenoid Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Wastegate Solenoid > Component Information > Service and Repair > Removal Wastegate Solenoid: Service and Repair Removal REMOVAL 1. Remove nuts (1) securing solenoid mounting bracket to shock tower. 2. Disconnect solenoid electrical connector. 3. Disconnect vacuum harness connector from solenoid. 4. Push on solenoid lock tab (1) and slide solenoid off bracket. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Wastegate Solenoid > Component Information > Service and Repair > Removal > Page 3974 Wastegate Solenoid: Service and Repair Installation INSTALLATION 1. Slide solenoid onto mounting bracket until lock tab engages. 2. Connect vacuum harness connector to solenoid. 3. Connect solenoid electrical connector. 4. Install nuts securing solenoid mounting bracket to shock tower. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Valve > Component Information > Locations Variable Induction Control Valve: Locations Component ID: 365 Component : VALVE-MANIFOLD FLOW Connector: Name : VALVE-MANIFOLD FLOW Color : BLACK # of pins : 6 Qualifier : (GAS) Pin Description Circuit 1 GROUND Z916 16BK 2-3 MFV CONTROL K601 20BR/VT 4 SENSOR GROUND K900 20DB/DG 5 MFV SIGNAL K602 20YL/DB 6 5 VOLT SUPPLY K857 20BR/LG Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Valve > Component Information > Locations > Page 3979 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Valve > Component Information > Locations > Page 3980 Variable Induction Control Valve: Diagrams Component ID: 365 Component : VALVE-MANIFOLD FLOW Connector: Name : VALVE-MANIFOLD FLOW Color : BLACK # of pins : 6 Qualifier : (GAS) Pin Description Circuit 1 GROUND Z916 16BK 2-3 MFV CONTROL K601 20BR/VT 4 SENSOR GROUND K900 20DB/DG 5 MFV SIGNAL K602 20YL/DB 6 5 VOLT SUPPLY K857 20BR/LG Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Valve > Component Information > Locations > Page 3981 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Valve > Component Information > Locations > Page 3982 Variable Induction Control Valve: Description and Operation OPERATION The World Engine is equipped with an intake manifold flow control valve to promote maximum air/fuel atomization. The valve restricts airflow, causing it to tumble or swirl. The tumbling action helps ensure that the fuel and air mix thoroughly and burn faster. The intake manifold flow control valve and variable valve timing work together to improve fuel economy, idle stability, and emissions. The electrically controlled intake manifold flow control valve is located in the intake manifold at the cylinder head. The intake manifold is constructed of composite material and divided into equal length runners. At the end of each runner is an intake manifold flow control valve flap. The intake manifold flow control valve actuator controls the flaps through a common shaft. The intake manifold flow control valve actuator is a two-position torque motor that is pulse-width driven by the GPEC1. The actuator is either energized to move the flaps out of the way to the wide-open position or de-energized to move the flaps up, to a restricted position. The intake manifold flow control valve actuator also contains a potentiometer feedback system to aid in diagnosis. The potentiometer circuit reports the actual position of the intake manifold flow control valve flaps. The GPEC1 compares the actual position with the desired position to ensure that the system is functioning correctly. The intake manifold flow control valve flaps are the mechanical components that restrict airflow to the intake ports. When the valves are moved upward, airflow is restricted and tumble occurs. When the valves are flat against the manifold, the full, unrestricted air charge flows to the intake ports. It is energized under specific operating conditions: At high engine speeds (greater than 3600 rpm on the 1.8 and 2.0 liter or greater than 4000 rpm on the 2.4 liter) or at wide-open throttle, the intake manifold flow control valve actuator is energized and the flaps move to the wide-open position, at lower engine speeds (less than 3600 rpm on the 1.8 and 2.0 liter or less than 4000 rpm on the 2.4 liter), the actuator is de-energized allowing the flaps to remain in the restricted position. The flap is held at that position by the return spring. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Valve > Component Information > Service and Repair > Removal Variable Induction Control Valve: Service and Repair Removal REMOVAL 1. Disconnect negative battery cable. 2. Remove air tube. 3. Disconnect electrical connector. 4. Remove 3 mounting screws. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Valve > Component Information > Service and Repair > Removal > Page 3985 5. Remove valve. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Valve > Component Information > Service and Repair > Removal > Page 3986 Variable Induction Control Valve: Service and Repair Installation INSTALLATION 1. Make sure that slot in shaft is not damaged. 2. Make sure that tab in valve is not damaged. 3. Align tab in valve with slot in intake manifold shaft (2) and rotate valve counterclock wise until valve drops onto location pin mounting (1). 4. Install mounting screws and tighten to 6 Nm (53 in.lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Valve > Component Information > Service and Repair > Removal > Page 3987 5. Connect electrical connector. 6. Install air tube. 7. Connect negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications Firing Order: Specifications DESCRIPTION The 2.4 Liter (148 cu. in.) in-line four cylinder engine is a double over head camshaft design with mechanical lash tappets and four valves per cylinder design. This engine is NOT free-wheeling; meaning that the pistons will contact the valves in the event of a timing chain failure. The cylinders are numbered from front of the engine to the rear. The firing order is 1-3-4-2. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Sensor-Camshaft 1/1 Position Camshaft Position Sensor: Locations Sensor-Camshaft 1/1 Position Component ID: 284 Component : SENSOR-CAMSHAFT 1/1 POSITION Connector: Name : SENSOR-CAMSHAFT 1/1 POSITION Color : BLACK # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY K857 20BR/LG 2 SENSOR GROUND K900 20DB/DG 3 CMP 1/1 SIGNAL K44 20DB Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Sensor-Camshaft 1/1 Position > Page 3996 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Sensor-Camshaft 1/1 Position > Page 3997 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Sensor-Camshaft 1/1 Position > Page 3998 Camshaft Position Sensor: Locations Sensor-Camshaft 1/2 Position Component ID: 285 Component : SENSOR-CAMSHAFT 1/2 POSITION Connector: Name : SENSOR-CAMSHAFT 1/2 POSITION Color : BLACK # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K915 20BR/WT 3 CMP 1/2 SIGNAL K441 20DB/BR Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Sensor-Camshaft 1/1 Position > Page 3999 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Sensor-Camshaft 1/1 Position Camshaft Position Sensor: Diagrams Sensor-Camshaft 1/1 Position Component ID: 284 Component : SENSOR-CAMSHAFT 1/1 POSITION Connector: Name : SENSOR-CAMSHAFT 1/1 POSITION Color : BLACK # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY K857 20BR/LG 2 SENSOR GROUND K900 20DB/DG 3 CMP 1/1 SIGNAL K44 20DB Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Sensor-Camshaft 1/1 Position > Page 4002 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Sensor-Camshaft 1/1 Position > Page 4003 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Sensor-Camshaft 1/1 Position > Page 4004 Camshaft Position Sensor: Diagrams Sensor-Camshaft 1/2 Position Component ID: 285 Component : SENSOR-CAMSHAFT 1/2 POSITION Connector: Name : SENSOR-CAMSHAFT 1/2 POSITION Color : BLACK # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K915 20BR/WT 3 CMP 1/2 SIGNAL K441 20DB/BR Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Sensor-Camshaft 1/1 Position > Page 4005 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Description Camshaft Position Sensor: Description and Operation Description DESCRIPTION The camshaft position sensors are mounted to the front and rear of the cylinder head. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Description > Page 4008 Camshaft Position Sensor: Description and Operation Operation OPERATION The PCM sends approximately 5 volts to the Hall-effect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. The input to the PCM occurs on a 5 volt output reference circuit. A ground for the sensor is provided through the sensor return circuit. The PCM identifies camshaft position by registering the change from 5 to 0 volts, as signaled from the camshaft position sensor. The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Removal Camshaft Position Sensor: Service and Repair Removal Front Camshaft Position Sensor FRONT CAMSHAFT POSITION SENSOR 1. Remove the air cleaner hose to throttle body, disconnect the inlet air temperature sensor electrical connector. 2. Disconnect negative battery cable. 3. Disconnect electrical connector from camshaft position sensor. 4. Remove camshaft position sensor mounting screws. 5. Remove sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 4011 Rear Camshaft Position Sensor REAR CAMSHAFT POSITION SENSOR 1. Disconnect negative battery cable. 2. Disconnect electrical connector at sensor. 3. Remove nut retaining heat shield. 4. Pull heat shield out to uncover sensor. 5. Remove mounting bolt. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 4012 6. Remove sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 4013 Camshaft Position Sensor: Service and Repair Installation Front Camshaft Position Sensor FRONT CAMSHAFT POSITION SENSOR 1. Lubricate sensor O-ring. 2. Install camshaft position sensor utilizing twisting motion. Make sure sensor is fully seated. Do not drive sensor into the bore with screw. This can cause sensor to be incorrectly seated causing engine to fail. Tighten sensor mounting screws to 9 Nm (79.5 in. lbs.). 3. Carefully attach electrical connector to camshaft position sensor. Installation at an angle may damage the sensor pins. 4. Install the negative battery cable. 5. Install the air cleaner to throttle body hose, connect the inlet air temperature sensor electrical connector. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 4014 Rear Camshaft Position Sensor REAR CAMSHAFT POSITION SENSOR 1. Lubricate sensor O-ring. 2. Install sensor utilizing twisting motion. Make sure sensor is fully seated. Do not drive sensor into the bore with screw. This can cause sensor to be incorrectly seated causing engine to fail. 3. Install mounting bolt and tighten to 9 Nm (79.5 in. lbs.). 4. Carefully attach electrical connector to camshaft position sensor. Fill for positive lock (click). Installation at angle may damage the sensor pins. 5. Install heat shield onto mounting stud. 6. Install heat shield retaining nut and tighten. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 4015 7. Connect the electrical connector. 8. Connect negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Condenser, Ignition > Component Information > Service and Repair > Removal Condenser: Service and Repair Removal REMOVAL 1. Disconnect the negative battery cable. 2. Remove the electrical connector from the ignition coil capacitor. 3. Remove mounting bolt and remove capacitor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Condenser, Ignition > Component Information > Service and Repair > Removal > Page 4020 Condenser: Service and Repair Installation INSTALLATION 1. Install coil capacitor (with connector facing rearward) and mounting bolt and tighten to 10 Nm (88.5 in. lbs.). 2. Connect the electrical connector. 3. Connect the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Component ID: 287 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 CKP SENSOR 5 VOLT SUPPLY K853 20DB/BR 2 CKP SENSOR SIGNAL K24 20BR/LB 3 CKP SENSOR GROUND K925 20DB/WT Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4024 Component Location - 19 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4025 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4026 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20LB/BR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4027 Component Location - 16 Component Location - 19 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4028 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4029 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4030 Crankshaft Position Sensor: Diagrams Component ID: 287 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 CKP SENSOR 5 VOLT SUPPLY K853 20DB/BR 2 CKP SENSOR SIGNAL K24 20BR/LB 3 CKP SENSOR GROUND K925 20DB/WT Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4031 Component Location - 19 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4032 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4033 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20LB/BR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4034 Component Location - 16 Component Location - 19 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4035 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4036 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description DESCRIPTION The crankshaft position sensor mounts to the rear of the engine block near the transmission. The PCM uses the Crankshaft Position sensor to calculate the following: - Engine RPM - TDC number 1 and 4 - Ignition coil synchronization - Injector synchronization - Camshaft-to-crankshaft misalignment (Timing belt skipped 1 tooth or more diagnostic trouble code). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 4039 Crankshaft Position Sensor: Description and Operation Operation OPERATION The PCM sends approximately 5 volts to the Hall-effect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. A ground for the sensor is provided through the sensor return circuit. The input to the PCM occurs on a 5 volt output reference circuit that operates as follows: The Hall-effect sensor contains a powerful magnet. As the magnetic field passes over the dense portion of the counterweight, the 5-volt signal is pulled to ground (0.3 volts) through a transistor in the sensor. When the magnetic field passes over the notches in the crankshaft counterweight, the magnetic field turns off the transistor in the sensor, causing the PCM to register the 5-volt signal. The PCM identifies crankshaft position by registering the change from 5 to 0 volts, as signaled from the Crankshaft Position sensor (2). The PCM determines which cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. The #8 crankshaft counterweight has a target ring with 32 teeth and notches (1), including one long reference tooth and notch. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Removal Crankshaft Position Sensor: Service and Repair Removal 2.0/2.4L The Crankshaft Position Sensor is in the rear of the engine block near the transmission. If vehicle is All Wheel Drive the Power Transfer Unit must be removed. 1. Disconnect the negative battery cable. 2. Raise vehicle and support. 3. Remove heat shield retaining bolt. 4. Remove heat shield. 5. Unlock and disconnect the electrical connector to the crankshaft position sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Removal > Page 4042 6. Remove the crankshaft position sensor bolt. 7. Remove the sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Removal > Page 4043 Crankshaft Position Sensor: Service and Repair Installation 2.0/2.4L 1. Check O-ring for damage and lubricate the O-ring with engine oil before installing sensor. 2. Use a twisting motion when installing the sensor. 3. Install and tighten the crankshaft position sensor bolt and tighten to 9 Nm (79.5 in. lbs.). 4. Connect and lock the electrical connector to the crankshaft position sensor. 5. Install heat shield and retaining bolt. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Removal > Page 4044 If vehicle is All Wheel Drive the Power Transfer Unit must be installed. 6. Lower vehicle. 7. Connect the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Capacitor-Ignition Ignition Coil: Locations Capacitor-Ignition Component ID: 43 Component : CAPACITOR-IGNITION Connector: Name : CAPACITOR-IGNITION Color : NATURAL # of pins : 1 Qualifier : (GAS) Pin Description Circuit 1 FUSED MAIN RELAY OUTPUT K344 16BR/GY Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Capacitor-Ignition > Page 4049 Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Capacitor-Ignition > Page 4050 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Capacitor-Ignition > Page 4051 Ignition Coil: Locations Coil-Ignition 1 Component ID: 45 Component : COIL-IGNITION 1 Connector: Name : COIL-IGNITION 1 Color : DK. GRAY # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1-2 COIL 1 CONTROL K19 18DG/LB 3 FUSED MAIN RELAY OUTPUT K344 18BR/GY Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Capacitor-Ignition > Page 4052 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Capacitor-Ignition > Page 4053 Ignition Coil: Locations Coil-Ignition 2 Component ID: 46 Component : COIL-IGNITION 2 Connector: Name : COIL-IGNITION 2 Color : DK. GRAY # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1-2 COIL 2 CONTROL K17 18DB/TN 3 FUSED MAIN RELAY OUTPUT K344 18BR/GY Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Capacitor-Ignition > Page 4054 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Capacitor-Ignition > Page 4055 Ignition Coil: Locations Coil-Ignition 3 Component ID: 47 Component : COIL-IGNITION 3 Connector: Name : COIL-IGNITION 3 Color : DK. GRAY # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1-2 COIL 3 CONTROL K18 18DB/OR 3 FUSED MAIN RELAY OUTPUT K344 18BR/GY Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Capacitor-Ignition > Page 4056 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Capacitor-Ignition > Page 4057 Ignition Coil: Locations Coil-Ignition 4 Component ID: 48 Component : COIL-IGNITION 4 Connector: Name : COIL-IGNITION 4 Color : DK. GRAY # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1-2 COIL 4 CONTROL K15 18GY/DB 3 FUSED MAIN RELAY OUTPUT K344 18BR/GY Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Capacitor-Ignition > Page 4058 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Capacitor-Ignition Ignition Coil: Diagrams Capacitor-Ignition Component ID: 43 Component : CAPACITOR-IGNITION Connector: Name : CAPACITOR-IGNITION Color : NATURAL # of pins : 1 Qualifier : (GAS) Pin Description Circuit 1 FUSED MAIN RELAY OUTPUT K344 16BR/GY Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Capacitor-Ignition > Page 4061 Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Capacitor-Ignition > Page 4062 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Capacitor-Ignition > Page 4063 Ignition Coil: Diagrams Coil-Ignition 1 Component ID: 45 Component : COIL-IGNITION 1 Connector: Name : COIL-IGNITION 1 Color : DK. GRAY # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1-2 COIL 1 CONTROL K19 18DG/LB 3 FUSED MAIN RELAY OUTPUT K344 18BR/GY Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Capacitor-Ignition > Page 4064 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Capacitor-Ignition > Page 4065 Ignition Coil: Diagrams Coil-Ignition 2 Component ID: 46 Component : COIL-IGNITION 2 Connector: Name : COIL-IGNITION 2 Color : DK. GRAY # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1-2 COIL 2 CONTROL K17 18DB/TN 3 FUSED MAIN RELAY OUTPUT K344 18BR/GY Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Capacitor-Ignition > Page 4066 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Capacitor-Ignition > Page 4067 Ignition Coil: Diagrams Coil-Ignition 3 Component ID: 47 Component : COIL-IGNITION 3 Connector: Name : COIL-IGNITION 3 Color : DK. GRAY # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1-2 COIL 3 CONTROL K18 18DB/OR 3 FUSED MAIN RELAY OUTPUT K344 18BR/GY Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Capacitor-Ignition > Page 4068 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Capacitor-Ignition > Page 4069 Ignition Coil: Diagrams Coil-Ignition 4 Component ID: 48 Component : COIL-IGNITION 4 Connector: Name : COIL-IGNITION 4 Color : DK. GRAY # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1-2 COIL 4 CONTROL K15 18GY/DB 3 FUSED MAIN RELAY OUTPUT K344 18BR/GY Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Capacitor-Ignition > Page 4070 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 4071 Ignition Coil: Description and Operation IGNITION SYSTEM NOTE: All engines use a fixed ignition timing system. Basic ignition timing is not adjustable. All spark advance is determined by the Powertrain Control Module (PCM). The ignition system used on these engines is referred to as the Direct Ignition System (DIS). The system's three main components are the coils, crankshaft position sensor, and camshaft position sensor. If equipped with the coil on plug ignition system it utilizes an ignition coil for every cylinder, it is mounted directly over each spark plug. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Service and Repair > Removal Ignition Coil: Service and Repair Removal 2.0/2.4L The electronic ignition coil attaches directly to the valve cover. 1. Remove the negative battery cable. 2. Disconnect electrical connector from ignition coil. 3. Remove ignition coil mounting bolts. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Service and Repair > Removal > Page 4074 4. Remove ignition coil. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Service and Repair > Removal > Page 4075 Ignition Coil: Service and Repair Installation 2.0/2.4L 1. Install ignition coil. 2. Tighten bolt to 9 Nm (79.5 in. lbs.). 3. Connect electrical connectors and lock. 4. Install the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Component ID: 299 Component : SENSOR-KNOCK Connector: Name : SENSOR-KNOCK Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 KS SIGNAL K42 20LG/DB 2 KS RETURN K942 20WT/BR Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 4079 Component Location - 15 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 4080 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 4081 Knock Sensor: Diagrams Component ID: 299 Component : SENSOR-KNOCK Connector: Name : SENSOR-KNOCK Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 KS SIGNAL K42 20LG/DB 2 KS RETURN K942 20WT/BR Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 4082 Component Location - 15 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 4083 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Description and Operation > Description Knock Sensor: Description and Operation Description DESCRIPTION The knock sensor is bolted to the cylinder block. The knock sensor is designed to detect engine vibration that is caused by detonation or preignition. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Description and Operation > Description > Page 4086 Knock Sensor: Description and Operation Operation OPERATION When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives as an input the knock sensor voltage signal. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, ignition timing retard is allowed. Ignition timing is retarded uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard ignition timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except WOT. The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening affects knock sensor performance, possibly causing improper spark control. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Service and Repair > Removal Knock Sensor: Service and Repair Removal 2.0/2.4L The knock sensor bolts into the side of the cylinder block in front of the starter under the intake manifold. 1. Disconnect the negative battery cable. 2. Remove the bolt holding the knock sensor. 3. Remove sensor with electrical connector attached. 4. Disconnect electrical connector from knock sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Service and Repair > Removal > Page 4089 5. Remove the knock sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Service and Repair > Removal > Page 4090 Knock Sensor: Service and Repair Installation 2.0/2.4L The knock sensor bolts into the side of the cylinder block in front of the starter under the intake manifold. 1. Attach electrical connector to knock sensor. 2. Install knock sensor. Tighten knock sensor bolt to 22 Nm (195 in. lbs.). Over or under tightening effects knock sensor performance, possibly causing improper spark control. 3. Connect the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Sensor-Camshaft 1/1 Position Camshaft Position Sensor: Locations Sensor-Camshaft 1/1 Position Component ID: 284 Component : SENSOR-CAMSHAFT 1/1 POSITION Connector: Name : SENSOR-CAMSHAFT 1/1 POSITION Color : BLACK # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY K857 20BR/LG 2 SENSOR GROUND K900 20DB/DG 3 CMP 1/1 SIGNAL K44 20DB Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Sensor-Camshaft 1/1 Position > Page 4096 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Sensor-Camshaft 1/1 Position > Page 4097 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Sensor-Camshaft 1/1 Position > Page 4098 Camshaft Position Sensor: Locations Sensor-Camshaft 1/2 Position Component ID: 285 Component : SENSOR-CAMSHAFT 1/2 POSITION Connector: Name : SENSOR-CAMSHAFT 1/2 POSITION Color : BLACK # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K915 20BR/WT 3 CMP 1/2 SIGNAL K441 20DB/BR Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Sensor-Camshaft 1/1 Position > Page 4099 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Sensor-Camshaft 1/1 Position Camshaft Position Sensor: Diagrams Sensor-Camshaft 1/1 Position Component ID: 284 Component : SENSOR-CAMSHAFT 1/1 POSITION Connector: Name : SENSOR-CAMSHAFT 1/1 POSITION Color : BLACK # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY K857 20BR/LG 2 SENSOR GROUND K900 20DB/DG 3 CMP 1/1 SIGNAL K44 20DB Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Sensor-Camshaft 1/1 Position > Page 4102 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Sensor-Camshaft 1/1 Position > Page 4103 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Sensor-Camshaft 1/1 Position > Page 4104 Camshaft Position Sensor: Diagrams Sensor-Camshaft 1/2 Position Component ID: 285 Component : SENSOR-CAMSHAFT 1/2 POSITION Connector: Name : SENSOR-CAMSHAFT 1/2 POSITION Color : BLACK # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K915 20BR/WT 3 CMP 1/2 SIGNAL K441 20DB/BR Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Sensor-Camshaft 1/1 Position > Page 4105 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Description Camshaft Position Sensor: Description and Operation Description DESCRIPTION The camshaft position sensors are mounted to the front and rear of the cylinder head. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Description > Page 4108 Camshaft Position Sensor: Description and Operation Operation OPERATION The PCM sends approximately 5 volts to the Hall-effect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. The input to the PCM occurs on a 5 volt output reference circuit. A ground for the sensor is provided through the sensor return circuit. The PCM identifies camshaft position by registering the change from 5 to 0 volts, as signaled from the camshaft position sensor. The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Removal Camshaft Position Sensor: Service and Repair Removal Front Camshaft Position Sensor FRONT CAMSHAFT POSITION SENSOR 1. Remove the air cleaner hose to throttle body, disconnect the inlet air temperature sensor electrical connector. 2. Disconnect negative battery cable. 3. Disconnect electrical connector from camshaft position sensor. 4. Remove camshaft position sensor mounting screws. 5. Remove sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 4111 Rear Camshaft Position Sensor REAR CAMSHAFT POSITION SENSOR 1. Disconnect negative battery cable. 2. Disconnect electrical connector at sensor. 3. Remove nut retaining heat shield. 4. Pull heat shield out to uncover sensor. 5. Remove mounting bolt. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 4112 6. Remove sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 4113 Camshaft Position Sensor: Service and Repair Installation Front Camshaft Position Sensor FRONT CAMSHAFT POSITION SENSOR 1. Lubricate sensor O-ring. 2. Install camshaft position sensor utilizing twisting motion. Make sure sensor is fully seated. Do not drive sensor into the bore with screw. This can cause sensor to be incorrectly seated causing engine to fail. Tighten sensor mounting screws to 9 Nm (79.5 in. lbs.). 3. Carefully attach electrical connector to camshaft position sensor. Installation at an angle may damage the sensor pins. 4. Install the negative battery cable. 5. Install the air cleaner to throttle body hose, connect the inlet air temperature sensor electrical connector. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 4114 Rear Camshaft Position Sensor REAR CAMSHAFT POSITION SENSOR 1. Lubricate sensor O-ring. 2. Install sensor utilizing twisting motion. Make sure sensor is fully seated. Do not drive sensor into the bore with screw. This can cause sensor to be incorrectly seated causing engine to fail. 3. Install mounting bolt and tighten to 9 Nm (79.5 in. lbs.). 4. Carefully attach electrical connector to camshaft position sensor. Fill for positive lock (click). Installation at angle may damage the sensor pins. 5. Install heat shield onto mounting stud. 6. Install heat shield retaining nut and tighten. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 4115 7. Connect the electrical connector. 8. Connect negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Component ID: 287 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 CKP SENSOR 5 VOLT SUPPLY K853 20DB/BR 2 CKP SENSOR SIGNAL K24 20BR/LB 3 CKP SENSOR GROUND K925 20DB/WT Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4119 Component Location - 19 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4120 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4121 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20LB/BR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4122 Component Location - 16 Component Location - 19 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4123 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4124 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4125 Crankshaft Position Sensor: Diagrams Component ID: 287 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 CKP SENSOR 5 VOLT SUPPLY K853 20DB/BR 2 CKP SENSOR SIGNAL K24 20BR/LB 3 CKP SENSOR GROUND K925 20DB/WT Component Location - 16 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4126 Component Location - 19 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4127 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4128 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20LB/BR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4129 Component Location - 16 Component Location - 19 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4130 Component Location - 17 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4131 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description DESCRIPTION The crankshaft position sensor mounts to the rear of the engine block near the transmission. The PCM uses the Crankshaft Position sensor to calculate the following: - Engine RPM - TDC number 1 and 4 - Ignition coil synchronization - Injector synchronization - Camshaft-to-crankshaft misalignment (Timing belt skipped 1 tooth or more diagnostic trouble code). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 4134 Crankshaft Position Sensor: Description and Operation Operation OPERATION The PCM sends approximately 5 volts to the Hall-effect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. A ground for the sensor is provided through the sensor return circuit. The input to the PCM occurs on a 5 volt output reference circuit that operates as follows: The Hall-effect sensor contains a powerful magnet. As the magnetic field passes over the dense portion of the counterweight, the 5-volt signal is pulled to ground (0.3 volts) through a transistor in the sensor. When the magnetic field passes over the notches in the crankshaft counterweight, the magnetic field turns off the transistor in the sensor, causing the PCM to register the 5-volt signal. The PCM identifies crankshaft position by registering the change from 5 to 0 volts, as signaled from the Crankshaft Position sensor (2). The PCM determines which cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. The #8 crankshaft counterweight has a target ring with 32 teeth and notches (1), including one long reference tooth and notch. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Removal Crankshaft Position Sensor: Service and Repair Removal 2.0/2.4L The Crankshaft Position Sensor is in the rear of the engine block near the transmission. If vehicle is All Wheel Drive the Power Transfer Unit must be removed. 1. Disconnect the negative battery cable. 2. Raise vehicle and support. 3. Remove heat shield retaining bolt. 4. Remove heat shield. 5. Unlock and disconnect the electrical connector to the crankshaft position sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Removal > Page 4137 6. Remove the crankshaft position sensor bolt. 7. Remove the sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Removal > Page 4138 Crankshaft Position Sensor: Service and Repair Installation 2.0/2.4L 1. Check O-ring for damage and lubricate the O-ring with engine oil before installing sensor. 2. Use a twisting motion when installing the sensor. 3. Install and tighten the crankshaft position sensor bolt and tighten to 9 Nm (79.5 in. lbs.). 4. Connect and lock the electrical connector to the crankshaft position sensor. 5. Install heat shield and retaining bolt. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Removal > Page 4139 If vehicle is All Wheel Drive the Power Transfer Unit must be installed. 6. Lower vehicle. 7. Connect the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder Ignition Switch Lock Cylinder: Service and Repair Key/Lock Cylinder Removal REMOVAL 1. Access and remove the Steering Column Control Module (SCCM) (3) from the steering column (2). 2. If equipped with Thatcham security (Export), remove the screws securing the cup (1) over the key cylinder. Remove the cup. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 4145 3. Remove the screw (1) fastening the SKREEM/WCM (2) to the lock cylinder housing (3). 4. Unhook the SKREEM/WCM (2) retainer fingers from the lock cylinder housing (3) and remove it. 5. Insert the key (2) and turn the key cylinder (3) to the RUN position. 6. Insert an appropriate tool into the slot (1) formed into the lock cylinder housing depressing the key cylinder retaining tab. 7. Pull the key cylinder and key straight out of the lock cylinder housing as one unit. 8. Using a Tamper-Proof Torx(R) Plus (five point) 30 bit, remove the two screws (1) fastening the lock cylinder housing (2) to the column. 9. Remove the lock cylinder housing from the steering column. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 4146 10. Remove the ignition module (2) mounting screw (1). 11. Pull the module (1) straight out and off the retaining tabs (2) located on the lock cylinder housing. Installation INSTALLATION NOTE: Ignition module must be installed prior to lock housing installation on column. Otherwise, the tilt lever will obstruct installation of ignition switch. 1. Ensure the ignition module is in the RUN position and the actuator shaft in the lock housing is in the RUN position. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 4147 2. Align the ignition module with the pin (3), actuator shaft and retaining tabs (2) located on the lock cylinder housing. Carefully install the module, snapping it into place over the retaining tabs. 3. Install the ignition module (2) mounting screw (1). Tighten the screw to 2 Nm (18 in. lbs.). NOTE: Ignition module needs to be installed on lock cylinder housing before housing installation to clear tilt lever. 4. Position the lock cylinder housing in the RUN position. 5. Align the lock cylinder housing (2) with the steering column. 6. Install the two screws (1) fastening the lock cylinder housing (2) to the column. Tighten the screws to 12 Nm (110 in. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 4148 7. Place the actuator in the lock cylinder housing to the RUN position (if not already there). 8. Insert the key into the key cylinder and turn the key cylinder to the RUN position. 9. Align the retaining tab on the key cylinder with the slot in the top of the lock cylinder housing. 10. Slide the key cylinder into the lock cylinder housing until the key cylinder retaining tab locks the cylinder into place. 11. Rotate the key back and forth (OFF to START), then remove and reinstall it, making sure the key cylinder and lock cylinder housing operate properly. 12. Slide the ring of the SKREEM/WCM (2) over the lock cylinder housing (3) and engage the retainer fingers in the recesses formed on the lock cylinder housing. 13. Install the screw (1) fastening the SKREEM/WCM (2) to the lock cylinder housing (3). Tighten the screw to 2.5 Nm (22 in. lbs.). 14. If equipped with Thatcham security (Export), install the cup (1) over the key cylinder and install the two mounting screws. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 4149 15. Install the Steering Column Control Module (SCCM) (3) and all components removed to access it. 16. Check operation of all steering column mounted components. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 4150 Ignition Switch Lock Cylinder: Service and Repair Housing-Lock Cylinder Removal REMOVAL 1. Access and remove the Steering Column Control Module (SCCM) (3) from the steering column (2). 2. If equipped with Thatcham security, remove the screws securing the cup (1) over the key cylinder. Remove the cup. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 4151 3. Remove the screw (1) fastening the SKREEM/WCM (2) to the lock cylinder housing (3). 4. Unhook the SKREEM/WCM (2) retainer fingers from the lock cylinder housing (3) and remove it. 5. Insert the key (2) and turn the key cylinder (3) to the RUN position. 6. Insert an appropriate tool into the slot (1) formed into the lock cylinder housing depressing the key cylinder retaining tab. 7. Pull the key cylinder and key straight out of the lock cylinder housing as one unit. 8. Using a Tamper-Proof Torx(R) Plus (five point) 30 bit, remove the two screws (1) fastening the lock cylinder housing (2) to the column. 9. Remove the lock cylinder housing from the steering column. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 4152 10. Remove the ignition module (2) mounting screw (1). 11. Pull the module (1) straight out and off the retaining tabs (2) located on the lock cylinder housing. Installation INSTALLATION NOTE: Ignition module must be installed prior to lock housing installation on column. Otherwise, the tilt lever will obstruct installation of ignition switch. 1. Ensure the ignition module is in the RUN position and the actuator shaft in the lock housing is in the RUN position. 2. Align the ignition module with the pin (3), actuator shaft and retaining tabs (2) located on the lock cylinder housing. Carefully install the module, snapping it into place over the retaining tabs. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 4153 3. Install the ignition module (2) mounting screw (1). Tighten the screw to 2 Nm (18 in. lbs.). NOTE: Ignition module needs to be installed on lock cylinder housing before housing installation to clear tilt lever. 4. Position the lock cylinder housing in the RUN position. 5. Align the lock cylinder housing (2) with the steering column. 6. Install the two screws (1) fastening the lock cylinder housing (2) to the column. Tighten the screws to 12 Nm (110 in. lbs.). 7. Place the actuator in the lock cylinder housing to the RUN position (if not already there). 8. Insert the key into the key cylinder and turn the key cylinder to the RUN position. 9. Align the retaining tab on the key cylinder with the slot in the top of the lock cylinder housing. 10. Slide the key cylinder into the lock cylinder housing until the key cylinder retaining tab locks the cylinder into place. 11. Rotate the key back and forth (OFF to START), then remove and reinstall it, making sure the key cylinder and lock cylinder housing operate Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 4154 properly. 12. Slide the ring of the SKREEM/WCM (2) over the lock cylinder housing (3) and engage the retainer fingers in the recesses formed on the lock cylinder housing. 13. Install the screw (1) fastening the SKREEM/WCM (2) to the lock cylinder housing (3). Tighten the screw to 2.5 Nm (22 in. lbs.). 14. If equipped with Thatcham security, install the cup (1) over the key cylinder and install the two mounting screws. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 4155 15. Install the Steering Column Control Module (SCCM) (3) and all components removed to access it. 16. Check operation of all steering column mounted components. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Component ID: 299 Component : SENSOR-KNOCK Connector: Name : SENSOR-KNOCK Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 KS SIGNAL K42 20LG/DB 2 KS RETURN K942 20WT/BR Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 4159 Component Location - 15 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 4160 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 4161 Knock Sensor: Diagrams Component ID: 299 Component : SENSOR-KNOCK Connector: Name : SENSOR-KNOCK Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 KS SIGNAL K42 20LG/DB 2 KS RETURN K942 20WT/BR Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 4162 Component Location - 15 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 4163 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Description Knock Sensor: Description and Operation Description DESCRIPTION The knock sensor is bolted to the cylinder block. The knock sensor is designed to detect engine vibration that is caused by detonation or preignition. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Description > Page 4166 Knock Sensor: Description and Operation Operation OPERATION When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives as an input the knock sensor voltage signal. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, ignition timing retard is allowed. Ignition timing is retarded uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard ignition timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except WOT. The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening affects knock sensor performance, possibly causing improper spark control. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Removal Knock Sensor: Service and Repair Removal 2.0/2.4L The knock sensor bolts into the side of the cylinder block in front of the starter under the intake manifold. 1. Disconnect the negative battery cable. 2. Remove the bolt holding the knock sensor. 3. Remove sensor with electrical connector attached. 4. Disconnect electrical connector from knock sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Removal > Page 4169 5. Remove the knock sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Removal > Page 4170 Knock Sensor: Service and Repair Installation 2.0/2.4L The knock sensor bolts into the side of the cylinder block in front of the starter under the intake manifold. 1. Attach electrical connector to knock sensor. 2. Install knock sensor. Tighten knock sensor bolt to 22 Nm (195 in. lbs.). Over or under tightening effects knock sensor performance, possibly causing improper spark control. 3. Connect the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications Spark Plug: Specifications SPARK PLUGS Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service and Repair > Removal Spark Plug: Service and Repair Removal 2.0/2.4L 1. Disconnect the negative battery cable. 2. Disconnect the electrical connectors from ignition coils. 3. Remove the ignition coil mounting bolt. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service and Repair > Removal > Page 4176 4. Twist the ignition coil then pull straight up. 5. Remove the spark plug using a quality socket with a rubber or foam insert. 6. Inspect the spark plug condition. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service and Repair > Removal > Page 4177 Spark Plug: Service and Repair Installation 2.0/2.4L Special care should be used when installing spark plugs in the cylinder head spark plug wells. Be sure the plugs do not drop into the wells, damage to the electrodes can occur. Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap. Overtightening can also damage the cylinder head. 1. To avoid cross threading, start the spark plug into the cylinder head by hand. 2. Tighten spark plugs to 17.5±2 Nm (13±2 ft. lbs.). 3. Install ignition coil on to spark plug. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service and Repair > Removal > Page 4178 4. Tighten coil mounting bolt. Tighten to 9 Nm (79.5 in. lbs.). 5. Connect electrical connectors and lock. 6. Connect the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor Control Module: Technical Service Bulletins Engine Controls - MIL On/DTC P0116/ECT Sensor NUMBER: 18-039-06 GROUP: Vehicle Performance DATE: December 6, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES FOR StarSCAN. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 7.02 SP2 OR HIGHER FOR THIS BULLETIN. SUBJECT: Flash: MIL Illumination DTC P0116 - Engine Coolant Temperature Sensor Performance OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) and the Transmission Control Module (1CM) with new software. CAUTION: VEHICLES EQUIPPED WITH A CVT TRANSMISSION MUST HAVE THE TRANSMISSION CONTROL MODULE (TCM) CHECKED FOR THE LATEST SOFTWARE LEVEL WHENEVER THE PCM SOFTWARE IS UPGRADED. IF NEWER TCM SOFTWARE IS AVAILABLE, IT MUST BE INSTALLED. MODELS: 2007 (PM) Caliber 2007 (MK49) Compass NOTE: This bulletin applies to PM/MK models equipped with a 1.8L, 2.0L or 2.4L gasoline engine (Sales Code EBA, ECN or ED3) and block heater (Sales Code NHK) built before November 20, 2006 (MDH 1120XX). NOTE: If an aftermarket or MOPAR accessory block heater is installed, the same conditions may apply. SYMPTOM/CONDITION: Some customers may experience MIL illumination after using the block heater. No other symptoms will be experienced. The technician may find the following DTC's: ^ P0116 - ENGINE COOLANT TEMPERATURE SENSOR PERFORMANCE DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If MIL illumination with DTC P0116 is present, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 4186 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING **STEP 5n and/or 8h**. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 7.02 SP2 software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. PM/MK Models equipped with a CVT must have the TCM reprogrammed as follows: 6. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. 7. Is the TCM part number recorded in step 6e above, the same as the new p/n shown on the "Flash File List" screen? a. Yes >> No further action is necessary. Proceed to Step 9. b. No >> the TCM will require flash reprogramming, proceed to Step 8. 8. Flash reprogram the TCM as follows: a. From the "Flash File List" screen, select "Download to Scantool". b. Select "Close" after the download is complete, then select "Back". c. Highlight the listed calibration. d. Select "Update Controller". Follow on screen instructions. e. When the update is complete, select "OK". f. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. g. Turn the ignition switch to the OFF position for no less than 15 seconds. h. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 4187 CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the TCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. ** NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 9. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 Control Module: Customer Interest A/T - MIL ON Possible DTC P2004 NUMBER: 18-032-07 GROUP: Vehicle Performance DATE: May 16, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 7.04 SPI OR HIGHER FOR THIS BULLETIN. SUBJECT: Flash: MIL Illumination with DIG P2004 OVERVIEW: This bulletin involves selectively erasing and reprogramming the GPEC Powertrain Control Module (PCM) with new software and replacing the intake manifold as required. CAUTION: VEHICLES EQUIPPED WITH A CVT TRANSMISSION MUST HAVE THE TRANSMISSION CONTROL MODULE (TCM) CHECKED FOR THE LATEST SOFTWARE LEVEL WHENEVER THE PCM SOFTWARE IS UPGRADED. IF NEWER TCM SOFTWARE IS AVAILABLE, IT MUST BE INSTALLED. MODELS: 2007-2008 (JS) Avenger 2007 (JS) Sebring 2008 (J527) Sebring Convertible 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to models equipped with a 1.8L, 2.0L or 2.4L gasoline engine (Sales Code EBA, ECN or ED3) as follows: Flash portion applies to PM/MK models built through April 21, 2007 (MDH 0421 XX) and JS models built through May 15, 2007 (0515XX). The Intake Manifold Replacement portion applies to models built through March 22, 2007 (MDHO322XX). SYMPTOM/CONDITION: Some customers may experience MIL Illumination with no other symptoms. The condition may occur intermittently. Further investigation by the technician may find DTC P2004 - Intake Manifold Runner Control Stuck Open as the cause for MIL Illumination. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine Systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Perform the standard diagnostic procedures for DIG P2004. If the diagnostics do not lead to the failure, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 4197 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and/or 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 7.04 SPI software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service> StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options d. Select "ECU Flash e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 4198 j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. m. Turn the ignition switch to the OFF position for no less than 15 seconds. n. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING 5n OR 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. PM/MK Models equipped with a CVT must have the TCM reprogrammed as follows: 6. Using the StarSCAN(R) at the "Home screen": a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. 7. Is the TCM part number recorded in step 6e above, the same as the new pin shown on the "Flash File List" screen? a. Yes > No further action is necessary. Proceed to Step 9. b. No > the TCM will require flash reprogramming, proceed to Step 8. 8. Flash reprogram the TCM as follows: a. From the "Flash File List screen, select "Download to Scantool". b. Select "Close" after the download is complete, then select "Back". c. Highlight the listed calibration. d. Select "Update Controller". Follow on screen instructions. e. When the update is complete, select "OK". f. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. g. Turn the ignition switch to the OFF position for no less than 15 seconds. h. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP Sn and 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the TCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list.** Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 4199 NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig.1). 1. Vehicles built through March 22, 2007 will require a new Intake Manifold pn 04884495AF. Following the procedures listed in DealerCONNECT > TechCONNECT replace the intake manifold. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B Technical Service Bulletin # 18-019-06 Date: 060607 A/T Controls - MIL ON/DTC's P0602/P167A or P161B NUMBER: 18-019-06 GROUP: Vehicle Performance DATE: June 7, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: Flash: MIL Illumination - DTC's P0602, P167A, or P161B OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (TCM) with new software and the Powertrain Control Module (PCM) with new software. WARNING: BOTH CONTROLLERS (TCM AND PCM) MUST BE REPROGRAMMED. THIS UPDATE MUST BE COMPLETED AS A COORDINATED CHANGE. IF THE PCM IS NOT UPDATED, MIL ILLUMINATION CAN OCCUR AND DTC U1424 (IMPLAUSIBLE ENGINE TORQUE MESSAGE RECEIVED) WILL BE RECORDED IN THE TCM. MODELS: 2007 (PM) Caliber NOTE: This bulletin applies to vehicles equipped with a Continuously Variable Transmission (CVT), (sales code DAV), built on or before June 1, 2006 (MDH 0601XX). SYMPTOM/CONDITION: The customer may experience Malfunction Indicator Lamp (MIL) illumination. The technician may find the following Diagnostic Trouble Codes (DTC's) in the TCM: ^ P0602-Control Module Programming Error/Not Programmed ^ P167A-Calibration Mismatch ^ P161B-Battery Disconnect / TCM Internal DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes MIL Illumination and the technician finds any of the DTC's listed above, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B > Page 4204 SPECIAL TOOLS / EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. TCM - Repair Procedure - Using the Internet to Retrieve the Flash File NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 6.06 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old TCM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B > Page 4205 b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". I. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. NOTE: Due to the TCM/PCM programming procedure, a DTC may be set in other modules (BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTC's". Press "Clear All Stored DTC's" if there are any DTC's shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 6. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). PCM Repair Procedure - Using the Internet to Retrieve the Flash File CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 6.06 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B > Page 4206 StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the PCM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. m. Turn the ignition switch to the OFF position for no less than 15 seconds. n. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 6. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 Control Module: All Technical Service Bulletins A/T - MIL ON Possible DTC P2004 NUMBER: 18-032-07 GROUP: Vehicle Performance DATE: May 16, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 7.04 SPI OR HIGHER FOR THIS BULLETIN. SUBJECT: Flash: MIL Illumination with DIG P2004 OVERVIEW: This bulletin involves selectively erasing and reprogramming the GPEC Powertrain Control Module (PCM) with new software and replacing the intake manifold as required. CAUTION: VEHICLES EQUIPPED WITH A CVT TRANSMISSION MUST HAVE THE TRANSMISSION CONTROL MODULE (TCM) CHECKED FOR THE LATEST SOFTWARE LEVEL WHENEVER THE PCM SOFTWARE IS UPGRADED. IF NEWER TCM SOFTWARE IS AVAILABLE, IT MUST BE INSTALLED. MODELS: 2007-2008 (JS) Avenger 2007 (JS) Sebring 2008 (J527) Sebring Convertible 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to models equipped with a 1.8L, 2.0L or 2.4L gasoline engine (Sales Code EBA, ECN or ED3) as follows: Flash portion applies to PM/MK models built through April 21, 2007 (MDH 0421 XX) and JS models built through May 15, 2007 (0515XX). The Intake Manifold Replacement portion applies to models built through March 22, 2007 (MDHO322XX). SYMPTOM/CONDITION: Some customers may experience MIL Illumination with no other symptoms. The condition may occur intermittently. Further investigation by the technician may find DTC P2004 - Intake Manifold Runner Control Stuck Open as the cause for MIL Illumination. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine Systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Perform the standard diagnostic procedures for DIG P2004. If the diagnostics do not lead to the failure, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 4212 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and/or 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 7.04 SPI software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service> StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options d. Select "ECU Flash e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 4213 j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. m. Turn the ignition switch to the OFF position for no less than 15 seconds. n. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING 5n OR 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. PM/MK Models equipped with a CVT must have the TCM reprogrammed as follows: 6. Using the StarSCAN(R) at the "Home screen": a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. 7. Is the TCM part number recorded in step 6e above, the same as the new pin shown on the "Flash File List" screen? a. Yes > No further action is necessary. Proceed to Step 9. b. No > the TCM will require flash reprogramming, proceed to Step 8. 8. Flash reprogram the TCM as follows: a. From the "Flash File List screen, select "Download to Scantool". b. Select "Close" after the download is complete, then select "Back". c. Highlight the listed calibration. d. Select "Update Controller". Follow on screen instructions. e. When the update is complete, select "OK". f. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. g. Turn the ignition switch to the OFF position for no less than 15 seconds. h. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP Sn and 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the TCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list.** Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 4214 NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig.1). 1. Vehicles built through March 22, 2007 will require a new Intake Manifold pn 04884495AF. Following the procedures listed in DealerCONNECT > TechCONNECT replace the intake manifold. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B Technical Service Bulletin # 18-019-06 Date: 060607 A/T Controls - MIL ON/DTC's P0602/P167A or P161B NUMBER: 18-019-06 GROUP: Vehicle Performance DATE: June 7, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: Flash: MIL Illumination - DTC's P0602, P167A, or P161B OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (TCM) with new software and the Powertrain Control Module (PCM) with new software. WARNING: BOTH CONTROLLERS (TCM AND PCM) MUST BE REPROGRAMMED. THIS UPDATE MUST BE COMPLETED AS A COORDINATED CHANGE. IF THE PCM IS NOT UPDATED, MIL ILLUMINATION CAN OCCUR AND DTC U1424 (IMPLAUSIBLE ENGINE TORQUE MESSAGE RECEIVED) WILL BE RECORDED IN THE TCM. MODELS: 2007 (PM) Caliber NOTE: This bulletin applies to vehicles equipped with a Continuously Variable Transmission (CVT), (sales code DAV), built on or before June 1, 2006 (MDH 0601XX). SYMPTOM/CONDITION: The customer may experience Malfunction Indicator Lamp (MIL) illumination. The technician may find the following Diagnostic Trouble Codes (DTC's) in the TCM: ^ P0602-Control Module Programming Error/Not Programmed ^ P167A-Calibration Mismatch ^ P161B-Battery Disconnect / TCM Internal DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes MIL Illumination and the technician finds any of the DTC's listed above, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B > Page 4219 SPECIAL TOOLS / EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. TCM - Repair Procedure - Using the Internet to Retrieve the Flash File NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 6.06 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old TCM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B > Page 4220 b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". I. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. NOTE: Due to the TCM/PCM programming procedure, a DTC may be set in other modules (BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTC's". Press "Clear All Stored DTC's" if there are any DTC's shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 6. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). PCM Repair Procedure - Using the Internet to Retrieve the Flash File CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 6.06 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B > Page 4221 StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the PCM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. m. Turn the ignition switch to the OFF position for no less than 15 seconds. n. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 6. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Description and Operation Transmission Speed Sensor: Description and Operation VEHICLE SPEED SENSOR The Vehicle Speed Sensor (VSS) is a hall effect sensor mounted above the transaxle differential. The sensor is triggered by the ring gear teeth passing below it. The VSS pulse signal to the speedometer/odometer is monitored by the PCM speed control circuitry to determine vehicle speed and to maintain speed control set speed. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Removal Transmission Speed Sensor: Service and Repair Removal REMOVAL 1. Open hood. 2. Remove the air cleaner housing. 3. Disconnect the speed sensor connector. CAUTION: Clean area around speed sensor before removing to prevent dirt from entering the transaxle during speed sensor removal. 4. Remove speed sensor retaining bolt. 5. Remove speed sensor from transaxle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Removal > Page 4229 Transmission Speed Sensor: Service and Repair Installation INSTALLATION 1. Using a NEW O-ring, install the speed sensor to the transaxle. 2. Install the bolt and tighten to 7 Nm (60 in. lbs.). 3. Connect speed sensor connector. 4. Install the air cleaner housing. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > F29 > Jul > 06 > Recall - Software Update for OBD Monitoring Technical Service Bulletin # F29 Date: 060701 Recall - Software Update for OBD Monitoring July 2006 Dealer Service Instructions for: Emissions Recall F29 Reprogram PCM OBD Thermostat Monitor Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Service Bulletin (TSB) # 18-020-06 has been cancelled for vehicles built through May 11, 2006. Models 2007 (PM) Dodge Caliber NOTE: This recall applies only to the above vehicles built through May 11, 2006 (MDH 051106). IMPORTANT: Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Powertrain Control Module (PCM) on about 29,600 on the above vehicles was inadvertently programmed with diagnostic software that is unable to detect an engine thermostat malfunction. As a result, the Malfunction Indicator Lamp will not illuminate if the thermostat fails. Repair The PCM must be reprogrammed (flashed). Parts Information Each dealer to whom vehicles in the recall were assigned will receive enough Authorized Modifications Labels to service about 20% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the labels shown. Special Tools Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > F29 > Jul > 06 > Recall - Software Update for OBD Monitoring > Page 4238 The existing special tools shown may be required to perform this repair. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive a copy of this dealer recall notification letter by mail. Two additional copies will be sent through the DCMMS. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > F29 > Jul > 06 > Recall - Software Update for OBD Monitoring > Page 4239 Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure Reprogram the Powertrain Control Module NOTE: This procedure must be performed with release 7.01 or later. To update your StarSCAN(R) diagnostic tool via the internet, the StarSCAN software must be at version 7.01 and properly configured to work with your dealership's network. 1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View" b. Touch the screen to highlight "PCM" in the list of modules. c. Select "More Options". d. Select "PCM Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "ECU Overview" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date and no further action is required. If the part number is different, continue with Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back" f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404 StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404 StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > F29 > Jul > 06 > Recall - Software Update for OBD Monitoring > Page 4240 a. Select "ECU View" b. Touch the screen to highlight "PCM" in the list of modules. c. Select "More Options". d. Select "PCM Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. NOTE: Due to the PCM programming procedure, a Diagnostic Trouble Code (DTC) may be set in other modules (ABS, TCM, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. B. Install the Authorized Modifications Label: 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. C. Complete Proof of Correction Form for California Residents: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > F29 > Jul > 06 > Recall - Software Update for OBD Monitoring > Page 4241 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > F29 > Jul > 06 > Recall - Software Update for OBD Monitoring > Page 4242 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-018-07A > May > 07 > Engine Controls - MIL ON/DTC's P0016/P0017/P000A/P000B PROM - Programmable Read Only Memory: Customer Interest Engine Controls - MIL ON/DTC's P0016/P0017/P000A/P000B NUMBER: 18-018-07 REV. A GROUP: Vehicle Performance DATE: May 30, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-018-07, DATED MARCH 2, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL DIAGNOSTIC CHECKS FOR APPROPRIATE OIL PRESSURE. THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 7.04 SP1 OR HIGHER FOR THIS BULLETIN. SUBJECT: Flash: MIL Illumination with DTC's P0016, P0017, P000A, or P000B OVERVIEW: This bulletin involves selectively erasing and reprogramming the GPEC Powertrain Control Module (PCM) with new software, **verifying oil pressure specifications**, replacing the intake and exhaust oil control valves (OCV), and replacing the engine oil and filter. CAUTION: VEHICLES EQUIPPED WITH A CVT TRANSMISSION MUST HAVE THE TRANSMISSION CONTROL MODULE (TCM) CHECKED FOR THE LATEST SOFTWARE LEVEL WHENEVER THE PCM SOFTWARE IS UPGRADED. IF NEWER TCM SOFTWARE IS AVAILABLE, IT MUST BE INSTALLED. MODELS: 2007 (JS) Sebring 2007-2008 (JS) Avenger 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to models equipped with a 1.8L, 2.0L or 2.4L gasoline engine (Sales Code EBA, ECN or ED3) on PM/MK models built before February 20, 2007 (MDH 0220XX) and JS models built before March 5, 2007 (M DH0305XX). SYMPTOM/CONDITION: Some customers may experience MIL illumination. Performance issues may or may not be experienced. The technician may find the following DTC's: ^ P0016-Crankshaft-Camshaft Timing Misalignment-Bank 1 Sensor 1. ^ P0017-Crankshaft-Camshaft Timing Misalignment-Bank 1 Sensor 2. ^ P000A-Bank 1 Camshaft 1 Position Slow Response. ^ P000B-Bank 1 Camshaft 2 Position Slow Response. The DTC's may be intermittent and difficult to duplicate. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-018-07A > May > 07 > Engine Controls - MIL ON/DTC's P0016/P0017/P000A/P000B > Page 4248 **Verify that the oil pressure meets specifications as listed in DealerCONNECT > TechCONNECT. If the oil pressure does not meet specifications, the OCV will be unable to function properly. In this case, further diagnosis will be required to determine the cause of inappropriate oil pressure.** **If the Oil Pressure meets specifications, DTC's are present and cannot be duplicated, perform the Repair Procedure**. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: FLASH REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and/or 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 7.04 SP1 software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN® Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN® ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-018-07A > May > 07 > Engine Controls - MIL ON/DTC's P0016/P0017/P000A/P000B > Page 4249 4. Power ON the StarSCAN(R). 5. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. m. Turn the ignition switch to the OFF position for no less than 15 seconds. n. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING 5n OR 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. PM/MK Models equipped with a CVT must have the TCM reprogrammed as follows: 6. Using the StarSCAN(R) at the "Home screen: a. Select "ECU View" b. Touch the screen to highlight the 1CM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. 7. Is the TCM part number recorded in step 6e above, the same as the new p/n shown on the "Flash File List" screen? a. Yes >> No further action is necessary. Proceed to Step 9. b. No >> the TCM will require flash reprogramming, proceed to Step 8. 8. Flash reprogram the 1CM as follows: a. From the "Flash File List screen, select "Download to Scantool". Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-018-07A > May > 07 > Engine Controls - MIL ON/DTC's P0016/P0017/P000A/P000B > Page 4250 b. Select "Close" after the download is complete, then select "Back". c. Highlight the listed calibration. d. Select "Update Controller". Follow on screen instructions. e. When the update is complete, select "OK". f. Verify the part number at the top of the "Flash TCM screen has updated to the new part number. g. Turn the ignition switch to the OFF position for no less than 15 seconds. h. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the TCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list.** NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 9. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). 10. Following the procedures listed in DealerCONNECT > TechCONNECT, replace both intake and exhaust Oil Control Valves pn 04884695AA and 04884483AA. 11. Replace the engine oil and filter. POLICY: Reimbursable within the provisions of the warranty. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-018-07A > May > 07 > Engine Controls - MIL ON/DTC's P0016/P0017/P000A/P000B > Page 4251 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 PROM - Programmable Read Only Memory: Customer Interest A/T - MIL ON Possible DTC P2004 NUMBER: 18-032-07 GROUP: Vehicle Performance DATE: May 16, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 7.04 SPI OR HIGHER FOR THIS BULLETIN. SUBJECT: Flash: MIL Illumination with DIG P2004 OVERVIEW: This bulletin involves selectively erasing and reprogramming the GPEC Powertrain Control Module (PCM) with new software and replacing the intake manifold as required. CAUTION: VEHICLES EQUIPPED WITH A CVT TRANSMISSION MUST HAVE THE TRANSMISSION CONTROL MODULE (TCM) CHECKED FOR THE LATEST SOFTWARE LEVEL WHENEVER THE PCM SOFTWARE IS UPGRADED. IF NEWER TCM SOFTWARE IS AVAILABLE, IT MUST BE INSTALLED. MODELS: 2007-2008 (JS) Avenger 2007 (JS) Sebring 2008 (J527) Sebring Convertible 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to models equipped with a 1.8L, 2.0L or 2.4L gasoline engine (Sales Code EBA, ECN or ED3) as follows: Flash portion applies to PM/MK models built through April 21, 2007 (MDH 0421 XX) and JS models built through May 15, 2007 (0515XX). The Intake Manifold Replacement portion applies to models built through March 22, 2007 (MDHO322XX). SYMPTOM/CONDITION: Some customers may experience MIL Illumination with no other symptoms. The condition may occur intermittently. Further investigation by the technician may find DTC P2004 - Intake Manifold Runner Control Stuck Open as the cause for MIL Illumination. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine Systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Perform the standard diagnostic procedures for DIG P2004. If the diagnostics do not lead to the failure, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 4256 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and/or 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 7.04 SPI software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service> StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options d. Select "ECU Flash e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 4257 j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. m. Turn the ignition switch to the OFF position for no less than 15 seconds. n. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING 5n OR 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. PM/MK Models equipped with a CVT must have the TCM reprogrammed as follows: 6. Using the StarSCAN(R) at the "Home screen": a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. 7. Is the TCM part number recorded in step 6e above, the same as the new pin shown on the "Flash File List" screen? a. Yes > No further action is necessary. Proceed to Step 9. b. No > the TCM will require flash reprogramming, proceed to Step 8. 8. Flash reprogram the TCM as follows: a. From the "Flash File List screen, select "Download to Scantool". b. Select "Close" after the download is complete, then select "Back". c. Highlight the listed calibration. d. Select "Update Controller". Follow on screen instructions. e. When the update is complete, select "OK". f. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. g. Turn the ignition switch to the OFF position for no less than 15 seconds. h. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP Sn and 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the TCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list.** Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 4258 NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig.1). 1. Vehicles built through March 22, 2007 will require a new Intake Manifold pn 04884495AF. Following the procedures listed in DealerCONNECT > TechCONNECT replace the intake manifold. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-033-06 > Nov > 06 > Engine Controls - MIL/Charge/Oil Lamps ON PROM - Programmable Read Only Memory: Customer Interest Engine Controls - MIL/Charge/Oil Lamps ON NUMBER: 18-033-06 GROUP: Vehicle Performance DATE:November 2, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES FOR StarSCAN. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 7.02 SPI OR HIGHER FOR THIS BULLETIN. SUBJECT: Flash: MIL Illumination/Generator Lamp Illumination/Oil Pressure Lamp Illumination/Driveability Improvements OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) and the Transmission Control Module (TCM) with new software and performing a memory reset to clear the adaptive memory of the PCM. CAUTION: VEHICLES (PM/MK) EQUIPPED WITH A CVT TRANSMISSION MUST HAVE THE TRANSMISSION CONTROL MODULE (TCM) CHECKED FOR THE LATEST SOFTWARE LEVEL WHENEVER THE PCM SOFTWARE IS UPGRADED. IF NEWER TCM SOFTWARE IS AVAILABLE, IT MUST BE INSTALLED. MODELS: 2007 (JS) Sebring 2007 (PM) Caliber 2007 (MK49) Compass NOTE: This bulletin applies to PM/MK models equipped with a 1.8L, 2.0L or 2.4L gasoline engine (Sales Code EBA, ECN or ED3) built before October 24, 2006 (MDH 1024XX). NOTE: This bulletin applies to JS models equipped with a 2.4L (Sales Code ED3) with the condition of momentary (1 to 2 second) oil indicator lamp illumination or flicker at idle and was originally addressed with RRT 06-048 Dated October 17, 2006. SYMPTOM/CONDITION: Some customers may experience MIL illumination, Intermittent Generator Lamp Illumination, Momentary (1 to 2 second) Oil indicator lamp illumination/flicker at idle or momentary delay returning to idle after clutch actuation. NOTE: Momentary oil lamp illumination at idle is due to oil pressure switch venting. This will NOT cause engine damage. This condition is most noticeable when the oil is hot, engine RPM is returned to idle and engine load from the power steering system is quickly applied. The technician may find one or more of the following DTC's or Symptoms: ^ P0139 - 02 Sensor 1/2 Slow Response. ^ P0700 - Transmission Control System (MIL REQUEST). This DTC is logged in PCM and when TCM is checked, DTC's are not present. ^ P063A - Generator Voltage Sense Circuit (Intermittent Generator Lamp Illumination). ^ Momentary (1 to 2 second) Oil Indicator Lamp Illumination or Flicker at Idle ^ Momentary Delay Returning to Idle when clutch is actuated (Vehicles Equipped with 2.4L Engine and Manual Transmission (Sales Code ED3 and DD7). DIAGNOSIS: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-033-06 > Nov > 06 > Engine Controls - MIL/Charge/Oil Lamps ON > Page 4263 Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If any of the above Symptom/Conditions are present, perform the Repair Procedure. If P0139 was present, verify exhaust system integrity after the reprogramming event by performing the drive cycle listed in TechCONNECT > Engine Electrical Diagnosis > Diagnosis and Testing > P0139, follow step 10. If P0139 reoccurs exhaust system leak checks and repairs will be required. Follow procedures listed in TechCONNECT > Engine Electrical Diagnosis > Diagnosis and Testing > Checking the Exhaust System for Leaks. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING **STEP 5n and/or 8h**. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 7.02 SPI software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN® diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN® for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-033-06 > Nov > 06 > Engine Controls - MIL/Charge/Oil Lamps ON > Page 4264 b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. m. Turn the ignition switch to the OFF position for no less than 15 seconds. n. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING 5n OR 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. PM/MK Models equipped with a CVT must have the TCM reprogrammed as follows: 6. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the 1CM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. 7. Is the TCM part number recorded in step 6e above, the same as the new pin shown on the "Flash File List" screen? a. Yes >> No further action is necessary. Proceed to Step # 9. b. No » the TCM will require flash reprogramming also, proceed to Step # 8. 8. Flash reprogram the TCM as follows: a. From the "Flash File List" screen, select "Download to Scantool". b. Select 'Close" after the download is complete, then select "Back". c. Highlight the listed calibration. d. Select "Update Controller". Follow on screen instructions. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-033-06 > Nov > 06 > Engine Controls - MIL/Charge/Oil Lamps ON > Page 4265 e. When the update is complete, select "OK". f. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. g. Turn the ignition switch to the OFF position for no less than 15 seconds. h. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the TCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. ** 9. Reset the adaptive memory of the PCM with the StarSCAN(R). Using the StarSCAN(R) at the "Home Screen": a. Select "ECU View". b. Highlight "PCM" in the list of modules; c. Select "Misc. Functions". d. Select "Reset Memory". e. Select "All Adaptive Memory". NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-033-06 > Nov > 06 > Engine Controls - MIL/Charge/Oil Lamps ON > Page 4266 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-020-06A > Sep > 06 > Engine Controls - Spark Knock When Warm/DTC P2173/P0452 PROM - Programmable Read Only Memory: Customer Interest Engine Controls - Spark Knock When Warm/DTC P2173/P0452 NUMBER: 18-020-06 REV. A GROUP: Vehicle Performance DATE: September 16, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-020-06 DATED JUNE 13, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES AN ADDITIONAL MODEL, REVISED SOFTWARE, CLEAN DATE, AND REVISED SYMPTOM/CONDITIONS, REPAIR PROCEDURES AND LABOR OPERATION NUMBERS THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES FOR StarSCAN. SUBJECT: Flash: Warm Weather Spark Knock and/or DIG P2173 **and/or P0452** OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) **and if necessary, the Transmission Control Module (TCM)** with new software and performing a memory reset to clear the adaptive memory of the PCM. MODELS: 2007 (PM) Caliber **2007 (MK49) Compass** NOTE: This bulletin applies to models equipped with a 2.0L or 2.4L gasoline engine and CVT transmission (sales code ECN or ED3 with DAV) built on or after May 11, 2006 (MDH 0511Xx) through and including August 16, 2006 (MDH 0816XX). SYMPTOM/CONDITION: Some customers may experience Spark Knock in warm ambient conditions (16°C (60°F) or higher). The technician may find one or more of the following DTC's. ^ P2173 - High Airflow/Vacuum Leak Detected (Slow Accumulation) may be found in the PCM. This DTC may occur when a vehicle is driven from a higher altitude to a lower altitude (1372 meter (4500 foot) change). ^ **P0452-Evap Pressure Switch Stuck Closed** DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the customer describes a Spark Knock condition, or the technician finds either DTC, perform the Repair Procedure. NOTE: If service bulletin 18-020-06 has been performed and the Symptom/Condition is still present, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-020-06A > Sep > 06 > Engine Controls - Spark Knock When Warm/DTC P2173/P0452 > Page 4271 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING **STEP 5n and 8h**. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 7.02 software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-020-06A > Sep > 06 > Engine Controls - Spark Knock When Warm/DTC P2173/P0452 > Page 4272 j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. m. Turn the ignition switch to the OFF position for no less than 15 seconds. n. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING 5n AND 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 6. **Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. 7. Is the TCM part number recorded in step 6e above, the same as the new p/n shown on the "Flash File List" screen? a. Yes >> No further action is necessary. Proceed to Step # 9. b. No >> the TCM will require flash reprogramming also, proceed to Step # 8. 8. Flash reprogram the TCM as follows: a. From the "Flash File List" screen, select "Download to Scantool". b. Select "Close" after the download is complete, then select "Back". c. Highlight the listed calibration. d. Select "Update Controller". Follow on screen instructions. e. When the update is complete, select "OK". f. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. g. Turn the ignition switch to the OFF position for no less than 15 seconds. h. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the TCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. ** 9. Reset the adaptive memory of the PCM with the StarSCAN®. This function is found under Miscellaneous Functions and is called Reset Memory. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-020-06A > Sep > 06 > Engine Controls - Spark Knock When Warm/DTC P2173/P0452 > Page 4273 Select All Adaptive Memory. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B Technical Service Bulletin # 18-019-06 Date: 060607 A/T Controls - MIL ON/DTC's P0602/P167A or P161B NUMBER: 18-019-06 GROUP: Vehicle Performance DATE: June 7, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: Flash: MIL Illumination - DTC's P0602, P167A, or P161B OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (TCM) with new software and the Powertrain Control Module (PCM) with new software. WARNING: BOTH CONTROLLERS (TCM AND PCM) MUST BE REPROGRAMMED. THIS UPDATE MUST BE COMPLETED AS A COORDINATED CHANGE. IF THE PCM IS NOT UPDATED, MIL ILLUMINATION CAN OCCUR AND DTC U1424 (IMPLAUSIBLE ENGINE TORQUE MESSAGE RECEIVED) WILL BE RECORDED IN THE TCM. MODELS: 2007 (PM) Caliber NOTE: This bulletin applies to vehicles equipped with a Continuously Variable Transmission (CVT), (sales code DAV), built on or before June 1, 2006 (MDH 0601XX). SYMPTOM/CONDITION: The customer may experience Malfunction Indicator Lamp (MIL) illumination. The technician may find the following Diagnostic Trouble Codes (DTC's) in the TCM: ^ P0602-Control Module Programming Error/Not Programmed ^ P167A-Calibration Mismatch ^ P161B-Battery Disconnect / TCM Internal DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes MIL Illumination and the technician finds any of the DTC's listed above, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B > Page 4278 SPECIAL TOOLS / EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. TCM - Repair Procedure - Using the Internet to Retrieve the Flash File NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 6.06 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old TCM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B > Page 4279 b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". I. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. NOTE: Due to the TCM/PCM programming procedure, a DTC may be set in other modules (BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTC's". Press "Clear All Stored DTC's" if there are any DTC's shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 6. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). PCM Repair Procedure - Using the Internet to Retrieve the Flash File CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 6.06 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B > Page 4280 StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the PCM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. m. Turn the ignition switch to the OFF position for no less than 15 seconds. n. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 6. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-015-06 > Apr > 06 > Engine Controls - MIL ON/DTC's P0071/P0139/P060F PROM - Programmable Read Only Memory: Customer Interest Engine Controls - MIL ON/DTC's P0071/P0139/P060F NUMBER: 18-015-06 GROUP: Vehicle Performance DATE: April 12, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES FOR StarSCAN. SUBJECT: Flash: MIL Illumination P0071, P0139, PO6OF, Immobilizer Secret Key to WCM Transfer, and DTC P0522 OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2007 (PM) Caliber NOTE: This bulletin applies to models equipped with a 1.8L, 2.0L, 2.4L gasoline engine (sales code EBA, ECN, or ED3) built on or before April 10, 2006 (MDH 0410XX). SYMPTOM/CONDITION: The Malfunction Indicator Lamp (MIL) may illuminate due to one or more of the following DTC's. ^ P0071 - AMBIENT AIR TEMPERATURE SENSOR PERFORMANCE ^ P0139 - 02 SENSOR 1/2 SLOW RESPONSE ^ P060F - ETC LEVEL 2 ECT PERFORMANCE In addition to MIL illumination with the above DTC's, changes have been made to address an error in DTC P0522 - Engine Oil Pressure Switch Circuit Low and writing the secret key to the WCM (Wireless Control Module) when a WCM is replaced. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above DTC's have been recorded or if Immobilizer keys cannot be registered after WCM replacement, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-015-06 > Apr > 06 > Engine Controls - MIL ON/DTC's P0071/P0139/P060F > Page 4285 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 6.05_5P4 level software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the appropriate ECU in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-015-06 > Apr > 06 > Engine Controls - MIL ON/DTC's P0071/P0139/P060F > Page 4286 i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. m. Turn the ignition switch to the OFF position for no less than 15 seconds. n. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the ECU programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 6. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-018-07A > May > 07 > Engine Controls - MIL ON/DTC's P0016/P0017/P000A/P000B PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0016/P0017/P000A/P000B NUMBER: 18-018-07 REV. A GROUP: Vehicle Performance DATE: May 30, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-018-07, DATED MARCH 2, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL DIAGNOSTIC CHECKS FOR APPROPRIATE OIL PRESSURE. THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 7.04 SP1 OR HIGHER FOR THIS BULLETIN. SUBJECT: Flash: MIL Illumination with DTC's P0016, P0017, P000A, or P000B OVERVIEW: This bulletin involves selectively erasing and reprogramming the GPEC Powertrain Control Module (PCM) with new software, **verifying oil pressure specifications**, replacing the intake and exhaust oil control valves (OCV), and replacing the engine oil and filter. CAUTION: VEHICLES EQUIPPED WITH A CVT TRANSMISSION MUST HAVE THE TRANSMISSION CONTROL MODULE (TCM) CHECKED FOR THE LATEST SOFTWARE LEVEL WHENEVER THE PCM SOFTWARE IS UPGRADED. IF NEWER TCM SOFTWARE IS AVAILABLE, IT MUST BE INSTALLED. MODELS: 2007 (JS) Sebring 2007-2008 (JS) Avenger 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to models equipped with a 1.8L, 2.0L or 2.4L gasoline engine (Sales Code EBA, ECN or ED3) on PM/MK models built before February 20, 2007 (MDH 0220XX) and JS models built before March 5, 2007 (M DH0305XX). SYMPTOM/CONDITION: Some customers may experience MIL illumination. Performance issues may or may not be experienced. The technician may find the following DTC's: ^ P0016-Crankshaft-Camshaft Timing Misalignment-Bank 1 Sensor 1. ^ P0017-Crankshaft-Camshaft Timing Misalignment-Bank 1 Sensor 2. ^ P000A-Bank 1 Camshaft 1 Position Slow Response. ^ P000B-Bank 1 Camshaft 2 Position Slow Response. The DTC's may be intermittent and difficult to duplicate. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-018-07A > May > 07 > Engine Controls - MIL ON/DTC's P0016/P0017/P000A/P000B > Page 4292 **Verify that the oil pressure meets specifications as listed in DealerCONNECT > TechCONNECT. If the oil pressure does not meet specifications, the OCV will be unable to function properly. In this case, further diagnosis will be required to determine the cause of inappropriate oil pressure.** **If the Oil Pressure meets specifications, DTC's are present and cannot be duplicated, perform the Repair Procedure**. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: FLASH REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and/or 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 7.04 SP1 software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN® Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN® ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-018-07A > May > 07 > Engine Controls - MIL ON/DTC's P0016/P0017/P000A/P000B > Page 4293 4. Power ON the StarSCAN(R). 5. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. m. Turn the ignition switch to the OFF position for no less than 15 seconds. n. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING 5n OR 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. PM/MK Models equipped with a CVT must have the TCM reprogrammed as follows: 6. Using the StarSCAN(R) at the "Home screen: a. Select "ECU View" b. Touch the screen to highlight the 1CM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. 7. Is the TCM part number recorded in step 6e above, the same as the new p/n shown on the "Flash File List" screen? a. Yes >> No further action is necessary. Proceed to Step 9. b. No >> the TCM will require flash reprogramming, proceed to Step 8. 8. Flash reprogram the 1CM as follows: a. From the "Flash File List screen, select "Download to Scantool". Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-018-07A > May > 07 > Engine Controls - MIL ON/DTC's P0016/P0017/P000A/P000B > Page 4294 b. Select "Close" after the download is complete, then select "Back". c. Highlight the listed calibration. d. Select "Update Controller". Follow on screen instructions. e. When the update is complete, select "OK". f. Verify the part number at the top of the "Flash TCM screen has updated to the new part number. g. Turn the ignition switch to the OFF position for no less than 15 seconds. h. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the TCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list.** NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 9. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). 10. Following the procedures listed in DealerCONNECT > TechCONNECT, replace both intake and exhaust Oil Control Valves pn 04884695AA and 04884483AA. 11. Replace the engine oil and filter. POLICY: Reimbursable within the provisions of the warranty. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-018-07A > May > 07 > Engine Controls - MIL ON/DTC's P0016/P0017/P000A/P000B > Page 4295 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T - MIL ON Possible DTC P2004 NUMBER: 18-032-07 GROUP: Vehicle Performance DATE: May 16, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 7.04 SPI OR HIGHER FOR THIS BULLETIN. SUBJECT: Flash: MIL Illumination with DIG P2004 OVERVIEW: This bulletin involves selectively erasing and reprogramming the GPEC Powertrain Control Module (PCM) with new software and replacing the intake manifold as required. CAUTION: VEHICLES EQUIPPED WITH A CVT TRANSMISSION MUST HAVE THE TRANSMISSION CONTROL MODULE (TCM) CHECKED FOR THE LATEST SOFTWARE LEVEL WHENEVER THE PCM SOFTWARE IS UPGRADED. IF NEWER TCM SOFTWARE IS AVAILABLE, IT MUST BE INSTALLED. MODELS: 2007-2008 (JS) Avenger 2007 (JS) Sebring 2008 (J527) Sebring Convertible 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to models equipped with a 1.8L, 2.0L or 2.4L gasoline engine (Sales Code EBA, ECN or ED3) as follows: Flash portion applies to PM/MK models built through April 21, 2007 (MDH 0421 XX) and JS models built through May 15, 2007 (0515XX). The Intake Manifold Replacement portion applies to models built through March 22, 2007 (MDHO322XX). SYMPTOM/CONDITION: Some customers may experience MIL Illumination with no other symptoms. The condition may occur intermittently. Further investigation by the technician may find DTC P2004 - Intake Manifold Runner Control Stuck Open as the cause for MIL Illumination. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine Systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Perform the standard diagnostic procedures for DIG P2004. If the diagnostics do not lead to the failure, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 4300 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and/or 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 7.04 SPI software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service> StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options d. Select "ECU Flash e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 4301 j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. m. Turn the ignition switch to the OFF position for no less than 15 seconds. n. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING 5n OR 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. PM/MK Models equipped with a CVT must have the TCM reprogrammed as follows: 6. Using the StarSCAN(R) at the "Home screen": a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. 7. Is the TCM part number recorded in step 6e above, the same as the new pin shown on the "Flash File List" screen? a. Yes > No further action is necessary. Proceed to Step 9. b. No > the TCM will require flash reprogramming, proceed to Step 8. 8. Flash reprogram the TCM as follows: a. From the "Flash File List screen, select "Download to Scantool". b. Select "Close" after the download is complete, then select "Back". c. Highlight the listed calibration. d. Select "Update Controller". Follow on screen instructions. e. When the update is complete, select "OK". f. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. g. Turn the ignition switch to the OFF position for no less than 15 seconds. h. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP Sn and 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the TCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list.** Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 4302 NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig.1). 1. Vehicles built through March 22, 2007 will require a new Intake Manifold pn 04884495AF. Following the procedures listed in DealerCONNECT > TechCONNECT replace the intake manifold. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-033-06 > Nov > 06 > Engine Controls - MIL/Charge/Oil Lamps ON PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls MIL/Charge/Oil Lamps ON NUMBER: 18-033-06 GROUP: Vehicle Performance DATE:November 2, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES FOR StarSCAN. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 7.02 SPI OR HIGHER FOR THIS BULLETIN. SUBJECT: Flash: MIL Illumination/Generator Lamp Illumination/Oil Pressure Lamp Illumination/Driveability Improvements OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) and the Transmission Control Module (TCM) with new software and performing a memory reset to clear the adaptive memory of the PCM. CAUTION: VEHICLES (PM/MK) EQUIPPED WITH A CVT TRANSMISSION MUST HAVE THE TRANSMISSION CONTROL MODULE (TCM) CHECKED FOR THE LATEST SOFTWARE LEVEL WHENEVER THE PCM SOFTWARE IS UPGRADED. IF NEWER TCM SOFTWARE IS AVAILABLE, IT MUST BE INSTALLED. MODELS: 2007 (JS) Sebring 2007 (PM) Caliber 2007 (MK49) Compass NOTE: This bulletin applies to PM/MK models equipped with a 1.8L, 2.0L or 2.4L gasoline engine (Sales Code EBA, ECN or ED3) built before October 24, 2006 (MDH 1024XX). NOTE: This bulletin applies to JS models equipped with a 2.4L (Sales Code ED3) with the condition of momentary (1 to 2 second) oil indicator lamp illumination or flicker at idle and was originally addressed with RRT 06-048 Dated October 17, 2006. SYMPTOM/CONDITION: Some customers may experience MIL illumination, Intermittent Generator Lamp Illumination, Momentary (1 to 2 second) Oil indicator lamp illumination/flicker at idle or momentary delay returning to idle after clutch actuation. NOTE: Momentary oil lamp illumination at idle is due to oil pressure switch venting. This will NOT cause engine damage. This condition is most noticeable when the oil is hot, engine RPM is returned to idle and engine load from the power steering system is quickly applied. The technician may find one or more of the following DTC's or Symptoms: ^ P0139 - 02 Sensor 1/2 Slow Response. ^ P0700 - Transmission Control System (MIL REQUEST). This DTC is logged in PCM and when TCM is checked, DTC's are not present. ^ P063A - Generator Voltage Sense Circuit (Intermittent Generator Lamp Illumination). ^ Momentary (1 to 2 second) Oil Indicator Lamp Illumination or Flicker at Idle ^ Momentary Delay Returning to Idle when clutch is actuated (Vehicles Equipped with 2.4L Engine and Manual Transmission (Sales Code ED3 and DD7). DIAGNOSIS: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-033-06 > Nov > 06 > Engine Controls - MIL/Charge/Oil Lamps ON > Page 4307 Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If any of the above Symptom/Conditions are present, perform the Repair Procedure. If P0139 was present, verify exhaust system integrity after the reprogramming event by performing the drive cycle listed in TechCONNECT > Engine Electrical Diagnosis > Diagnosis and Testing > P0139, follow step 10. If P0139 reoccurs exhaust system leak checks and repairs will be required. Follow procedures listed in TechCONNECT > Engine Electrical Diagnosis > Diagnosis and Testing > Checking the Exhaust System for Leaks. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING **STEP 5n and/or 8h**. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 7.02 SPI software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN® diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN® for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-033-06 > Nov > 06 > Engine Controls - MIL/Charge/Oil Lamps ON > Page 4308 b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. m. Turn the ignition switch to the OFF position for no less than 15 seconds. n. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING 5n OR 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. PM/MK Models equipped with a CVT must have the TCM reprogrammed as follows: 6. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the 1CM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. 7. Is the TCM part number recorded in step 6e above, the same as the new pin shown on the "Flash File List" screen? a. Yes >> No further action is necessary. Proceed to Step # 9. b. No » the TCM will require flash reprogramming also, proceed to Step # 8. 8. Flash reprogram the TCM as follows: a. From the "Flash File List" screen, select "Download to Scantool". b. Select 'Close" after the download is complete, then select "Back". c. Highlight the listed calibration. d. Select "Update Controller". Follow on screen instructions. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-033-06 > Nov > 06 > Engine Controls - MIL/Charge/Oil Lamps ON > Page 4309 e. When the update is complete, select "OK". f. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. g. Turn the ignition switch to the OFF position for no less than 15 seconds. h. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the TCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. ** 9. Reset the adaptive memory of the PCM with the StarSCAN(R). Using the StarSCAN(R) at the "Home Screen": a. Select "ECU View". b. Highlight "PCM" in the list of modules; c. Select "Misc. Functions". d. Select "Reset Memory". e. Select "All Adaptive Memory". NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-033-06 > Nov > 06 > Engine Controls - MIL/Charge/Oil Lamps ON > Page 4310 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-020-06A > Sep > 06 > Engine Controls - Spark Knock When Warm/DTC P2173/P0452 PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Spark Knock When Warm/DTC P2173/P0452 NUMBER: 18-020-06 REV. A GROUP: Vehicle Performance DATE: September 16, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-020-06 DATED JUNE 13, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES AN ADDITIONAL MODEL, REVISED SOFTWARE, CLEAN DATE, AND REVISED SYMPTOM/CONDITIONS, REPAIR PROCEDURES AND LABOR OPERATION NUMBERS THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES FOR StarSCAN. SUBJECT: Flash: Warm Weather Spark Knock and/or DIG P2173 **and/or P0452** OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) **and if necessary, the Transmission Control Module (TCM)** with new software and performing a memory reset to clear the adaptive memory of the PCM. MODELS: 2007 (PM) Caliber **2007 (MK49) Compass** NOTE: This bulletin applies to models equipped with a 2.0L or 2.4L gasoline engine and CVT transmission (sales code ECN or ED3 with DAV) built on or after May 11, 2006 (MDH 0511Xx) through and including August 16, 2006 (MDH 0816XX). SYMPTOM/CONDITION: Some customers may experience Spark Knock in warm ambient conditions (16°C (60°F) or higher). The technician may find one or more of the following DTC's. ^ P2173 - High Airflow/Vacuum Leak Detected (Slow Accumulation) may be found in the PCM. This DTC may occur when a vehicle is driven from a higher altitude to a lower altitude (1372 meter (4500 foot) change). ^ **P0452-Evap Pressure Switch Stuck Closed** DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the customer describes a Spark Knock condition, or the technician finds either DTC, perform the Repair Procedure. NOTE: If service bulletin 18-020-06 has been performed and the Symptom/Condition is still present, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-020-06A > Sep > 06 > Engine Controls - Spark Knock When Warm/DTC P2173/P0452 > Page 4315 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING **STEP 5n and 8h**. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 7.02 software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-020-06A > Sep > 06 > Engine Controls - Spark Knock When Warm/DTC P2173/P0452 > Page 4316 j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. m. Turn the ignition switch to the OFF position for no less than 15 seconds. n. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING 5n AND 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 6. **Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. 7. Is the TCM part number recorded in step 6e above, the same as the new p/n shown on the "Flash File List" screen? a. Yes >> No further action is necessary. Proceed to Step # 9. b. No >> the TCM will require flash reprogramming also, proceed to Step # 8. 8. Flash reprogram the TCM as follows: a. From the "Flash File List" screen, select "Download to Scantool". b. Select "Close" after the download is complete, then select "Back". c. Highlight the listed calibration. d. Select "Update Controller". Follow on screen instructions. e. When the update is complete, select "OK". f. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. g. Turn the ignition switch to the OFF position for no less than 15 seconds. h. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the TCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. ** 9. Reset the adaptive memory of the PCM with the StarSCAN®. This function is found under Miscellaneous Functions and is called Reset Memory. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-020-06A > Sep > 06 > Engine Controls - Spark Knock When Warm/DTC P2173/P0452 > Page 4317 Select All Adaptive Memory. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-001-06A > Jul > 06 > Engine Controls - Flash Reprogramming Abort Recovery PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Flash Reprogramming Abort Recovery NUMBER: 18-001-06 REV. A GROUP: Vehicle Performance DATE: July 12, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-001-06, DATED JANUARY II, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, YEARS AND A REVISED DISCUSSION ABOUT ABORTED FLASH REPROGRAMMING RECOVERY. SUBJECT: StarSCAN(R)/StarMOBILE(TM) Abort Recovery Procedures OVERVIEW: This Bulletin provides guidelines to minimize flash reprogramming problems and recovery procedure information for failed flash attempts. MODELS: **2007 (DC) Ram Cab & Chassis** 2006 - **2007** (DR/DH/D1) Ram Truck 2004 - **2007** (HB/HG) Durango/Aspen 2007 (JK) Wrangler **2007 (JS) Sebring** **2007 (KA) Nitro** 2006 - **2007** (KJ) Liberty/Cherokee 2005 - **2007** (LX/LE) 300/Magnum/Charger **2007 (MK) Compass** 2005 - **2007** (ND) Dakota **2007 (PM) Caliber** 2006 - **2007* (PT) PT Cruiser 2005 - **2007** (WK/WH) Grand Cherokee 2006 - **2007** (XK/XH) Commander DISCUSSION: NOTE: Many of the reasons a flash reprogramming procedure may not complete are documented in this service bulletin. Occasionally a flash update procedure may not complete properly and/or the diagnostic equipment may lock up or become disconnected during the procedure. Flash Reprogramming is a "CRITICAL PROCESS"; an error may result in a no-start/failed control module. Most modules, encountering an interruption or failure while reprogramming, are recoverable. Replacing a module that is recoverable is not covered under the provisions of the warranty. This service bulletin covers items that may cause this condition, a process to restart the flash procedure, and miscellaneous information that will help prevent unnecessary replacement of control modules. GENERAL: Flash Reprogramming is only authorized when programming a generic module or by a specific SERVICE ACTION (Service Bulletin/Recall/Rapid Response Transmittal/Advance Service Information). CAUTION: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-001-06A > Jul > 06 > Engine Controls - Flash Reprogramming Abort Recovery > Page 4322 When updating a module because of a Service Action, it is important to follow the steps outlined in the Repair Procedure section of the Service Action. Procedures may differ depending on the module that is being reprogrammed. Review the entire Service Action prior to performing a flash reprogramming update. Often other parts may need to be serviced, replaced, or tested, prior to flash reprogramming, and ARE REQUIRED as part of completing the Service Action. COMMON CAUSES OF FLASH REPROGRAMMING ERRORS Interruptions, voltage problems, a variety of other outside interactions, and failure to follow the steps outlined in the Service Action can potentially interfere with the process. This document seeks to provide information to minimize problems associated with module flash reprogramming. SOFTWARE VERSIONS MUST BE CURRENT Before attempting a flash reprogramming session, make sure you have the most current software installed in the scan tool (StarSCAN(R)/StarMOBILE(TM)). Refer to the current software release information available in TechCONNECT, under: Service Info > StarSCAN(R) and StarMOBILE(TM) Tools > Latest News > Select the most recent release number. The technician will be able to see the applicable version numbers. Often, because of multiple StarSCAN(R)/StarMOBILE(TM)s in the shop, not all devices will get updated in a timely manner. The installed StarSCAN(R)/StarMOBILE(TM) software version and scan tool operating system version, (Fig. 2), can be verified from the "Home" screen as follows: StarMOBILE Desktop Client ^ Select "Tool Menu". ^ Select "Version Information" Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-001-06A > Jul > 06 > Engine Controls - Flash Reprogramming Abort Recovery > Page 4323 StarSCAN ^ Select "Show Shortcuts" ^ Select "Tool Menu". ^ Select "Version Information" Typical Tool Menu (Fig. 1) NOTE: The StarSCAN also displays the version number on the right side of the blue header at the top of each screen. NOTE: To read the version on the StarMOBILE(TM), it must be connected and the application running or the user will receive "N/A" for the "System" value. GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS Consider ALL cables to be wear items. It is a good practice to have dedicated cables devoted to "Flash ONLY". Always have a spare StarSCAN(R) CH9404 (vehicle) cable available. Always have a spare StarMOBILE(TM) CH9804 (vehicle) cable available (blue cable end). Diagnosing vehicle cable problems Inspect vehicle cable connectors for potential problems that might cause communication interruptions. Use the information available on DealerCONNECT under: ^ eSupport (above the "Marketing" tab) ^ Under "Knowledge Center" - select "Find Answers" ^ In the "Enter link, error message, or topic" area, type "561" ^ In the "Search By" area, select "Answer ID" ^ At the next screen, select the "StarSCAN Flash Lockup.pdf" link to access the information to diagnose suspect vehicle cable continuity. FLASH REPROGRAMMING PROBLEM PREVENTION ^ Follow the steps outlined in the Service Action. ^ Pay attention to the screen prompts displayed during the flash process. ^ Replace worn cables. ^ Verify the vehicle is equipped with a known good battery. ^ Ensure the battery charger charging rate provides approximately 13.2 - 13.8 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. **ABORTED FLASH REPROGRAMMING RECOVERY** ** The following steps may help recover a non-responsive module when the flash process is aborted or interrupted. 1. When the Flash ECU screen displays an Error Message, select OK. 2. Turn the ignition to "off" and power down the StarSCAN(R). 3. Turn the vehicle ignition to the "On" position. 4. Power on the StarSCAN®. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-001-06A > Jul > 06 > Engine Controls - Flash Reprogramming Abort Recovery > Page 4324 NOTE: If the technician was flashing a PCM, the tool may display "Unknown VIN". Disregard this. 5. Select (ECU) View. 6. Highlight the ECU that was being flashed. NOTE: The module may appear to be non-responsive. Highlight the module anyway. 7. Select More Options 8. Select ECU Flash 9. If the "Flash ECU" screen displays "Resident flash files for Part # XXXXX", the module should be recoverable. If the screen displays "No resident flash files found" the module is not recoverable. Does the Flash ECU screen display "No resident flash files found?" a. Yes >> The module must be replaced. b. No >> proceed to Step # 10. 10. Is a calibration file displayed on the StarSCAN(R)? a. Yes >> proceed to Step # 11. b. No >> Select "Browse For New File" and follow on screen instructions. Highlight the calibration that was previously chosen. Select "Download to Scantool". When the file is downloaded to the scantool, select "Back" and proceed to Step # 11. 11. Highlight the appropriate calibration. 12. Select "Update Controller" and follow the on screen instructions. 13. When the flash is complete, verify the "Resident flash file part number" matches the 'New PIN" of the appropriate calibration. 14. Proceed with the steps listed in the Service Bulletin to complete the service action.** NOTE: If after following the steps above, you are still having issues performing the flash reprogramming procedure using a specific StarSCAN(R)/StarMOBILE(R) it is suggested to contact SPX/Miller Special Tools for service. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > F29 > Jul > 06 > Recall - Software Update for OBD Monitoring Technical Service Bulletin # F29 Date: 060701 Recall - Software Update for OBD Monitoring July 2006 Dealer Service Instructions for: Emissions Recall F29 Reprogram PCM OBD Thermostat Monitor Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Service Bulletin (TSB) # 18-020-06 has been cancelled for vehicles built through May 11, 2006. Models 2007 (PM) Dodge Caliber NOTE: This recall applies only to the above vehicles built through May 11, 2006 (MDH 051106). IMPORTANT: Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Powertrain Control Module (PCM) on about 29,600 on the above vehicles was inadvertently programmed with diagnostic software that is unable to detect an engine thermostat malfunction. As a result, the Malfunction Indicator Lamp will not illuminate if the thermostat fails. Repair The PCM must be reprogrammed (flashed). Parts Information Each dealer to whom vehicles in the recall were assigned will receive enough Authorized Modifications Labels to service about 20% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the labels shown. Special Tools Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > F29 > Jul > 06 > Recall - Software Update for OBD Monitoring > Page 4329 The existing special tools shown may be required to perform this repair. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive a copy of this dealer recall notification letter by mail. Two additional copies will be sent through the DCMMS. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > F29 > Jul > 06 > Recall - Software Update for OBD Monitoring > Page 4330 Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure Reprogram the Powertrain Control Module NOTE: This procedure must be performed with release 7.01 or later. To update your StarSCAN(R) diagnostic tool via the internet, the StarSCAN software must be at version 7.01 and properly configured to work with your dealership's network. 1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View" b. Touch the screen to highlight "PCM" in the list of modules. c. Select "More Options". d. Select "PCM Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "ECU Overview" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date and no further action is required. If the part number is different, continue with Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back" f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404 StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404 StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > F29 > Jul > 06 > Recall - Software Update for OBD Monitoring > Page 4331 a. Select "ECU View" b. Touch the screen to highlight "PCM" in the list of modules. c. Select "More Options". d. Select "PCM Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. NOTE: Due to the PCM programming procedure, a Diagnostic Trouble Code (DTC) may be set in other modules (ABS, TCM, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. B. Install the Authorized Modifications Label: 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. C. Complete Proof of Correction Form for California Residents: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > F29 > Jul > 06 > Recall - Software Update for OBD Monitoring > Page 4332 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > F29 > Jul > 06 > Recall - Software Update for OBD Monitoring > Page 4333 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B Technical Service Bulletin # 18-019-06 Date: 060607 A/T Controls - MIL ON/DTC's P0602/P167A or P161B NUMBER: 18-019-06 GROUP: Vehicle Performance DATE: June 7, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: Flash: MIL Illumination - DTC's P0602, P167A, or P161B OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (TCM) with new software and the Powertrain Control Module (PCM) with new software. WARNING: BOTH CONTROLLERS (TCM AND PCM) MUST BE REPROGRAMMED. THIS UPDATE MUST BE COMPLETED AS A COORDINATED CHANGE. IF THE PCM IS NOT UPDATED, MIL ILLUMINATION CAN OCCUR AND DTC U1424 (IMPLAUSIBLE ENGINE TORQUE MESSAGE RECEIVED) WILL BE RECORDED IN THE TCM. MODELS: 2007 (PM) Caliber NOTE: This bulletin applies to vehicles equipped with a Continuously Variable Transmission (CVT), (sales code DAV), built on or before June 1, 2006 (MDH 0601XX). SYMPTOM/CONDITION: The customer may experience Malfunction Indicator Lamp (MIL) illumination. The technician may find the following Diagnostic Trouble Codes (DTC's) in the TCM: ^ P0602-Control Module Programming Error/Not Programmed ^ P167A-Calibration Mismatch ^ P161B-Battery Disconnect / TCM Internal DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes MIL Illumination and the technician finds any of the DTC's listed above, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B > Page 4338 SPECIAL TOOLS / EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. TCM - Repair Procedure - Using the Internet to Retrieve the Flash File NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 6.06 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old TCM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B > Page 4339 b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". I. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. NOTE: Due to the TCM/PCM programming procedure, a DTC may be set in other modules (BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTC's". Press "Clear All Stored DTC's" if there are any DTC's shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 6. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). PCM Repair Procedure - Using the Internet to Retrieve the Flash File CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 6.06 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B > Page 4340 StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the PCM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. m. Turn the ignition switch to the OFF position for no less than 15 seconds. n. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 6. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-015-06 > Apr > 06 > Engine Controls - MIL ON/DTC's P0071/P0139/P060F PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0071/P0139/P060F NUMBER: 18-015-06 GROUP: Vehicle Performance DATE: April 12, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES FOR StarSCAN. SUBJECT: Flash: MIL Illumination P0071, P0139, PO6OF, Immobilizer Secret Key to WCM Transfer, and DTC P0522 OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2007 (PM) Caliber NOTE: This bulletin applies to models equipped with a 1.8L, 2.0L, 2.4L gasoline engine (sales code EBA, ECN, or ED3) built on or before April 10, 2006 (MDH 0410XX). SYMPTOM/CONDITION: The Malfunction Indicator Lamp (MIL) may illuminate due to one or more of the following DTC's. ^ P0071 - AMBIENT AIR TEMPERATURE SENSOR PERFORMANCE ^ P0139 - 02 SENSOR 1/2 SLOW RESPONSE ^ P060F - ETC LEVEL 2 ECT PERFORMANCE In addition to MIL illumination with the above DTC's, changes have been made to address an error in DTC P0522 - Engine Oil Pressure Switch Circuit Low and writing the secret key to the WCM (Wireless Control Module) when a WCM is replaced. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above DTC's have been recorded or if Immobilizer keys cannot be registered after WCM replacement, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-015-06 > Apr > 06 > Engine Controls - MIL ON/DTC's P0071/P0139/P060F > Page 4345 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 6.05_5P4 level software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the appropriate ECU in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-015-06 > Apr > 06 > Engine Controls - MIL ON/DTC's P0071/P0139/P060F > Page 4346 i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. m. Turn the ignition switch to the OFF position for no less than 15 seconds. n. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the ECU programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 6. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-018-07A > May > 07 > Engine Controls - MIL ON/DTC's P0016/P0017/P000A/P000B PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0016/P0017/P000A/P000B NUMBER: 18-018-07 REV. A GROUP: Vehicle Performance DATE: May 30, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-018-07, DATED MARCH 2, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL DIAGNOSTIC CHECKS FOR APPROPRIATE OIL PRESSURE. THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 7.04 SP1 OR HIGHER FOR THIS BULLETIN. SUBJECT: Flash: MIL Illumination with DTC's P0016, P0017, P000A, or P000B OVERVIEW: This bulletin involves selectively erasing and reprogramming the GPEC Powertrain Control Module (PCM) with new software, **verifying oil pressure specifications**, replacing the intake and exhaust oil control valves (OCV), and replacing the engine oil and filter. CAUTION: VEHICLES EQUIPPED WITH A CVT TRANSMISSION MUST HAVE THE TRANSMISSION CONTROL MODULE (TCM) CHECKED FOR THE LATEST SOFTWARE LEVEL WHENEVER THE PCM SOFTWARE IS UPGRADED. IF NEWER TCM SOFTWARE IS AVAILABLE, IT MUST BE INSTALLED. MODELS: 2007 (JS) Sebring 2007-2008 (JS) Avenger 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to models equipped with a 1.8L, 2.0L or 2.4L gasoline engine (Sales Code EBA, ECN or ED3) on PM/MK models built before February 20, 2007 (MDH 0220XX) and JS models built before March 5, 2007 (M DH0305XX). SYMPTOM/CONDITION: Some customers may experience MIL illumination. Performance issues may or may not be experienced. The technician may find the following DTC's: ^ P0016-Crankshaft-Camshaft Timing Misalignment-Bank 1 Sensor 1. ^ P0017-Crankshaft-Camshaft Timing Misalignment-Bank 1 Sensor 2. ^ P000A-Bank 1 Camshaft 1 Position Slow Response. ^ P000B-Bank 1 Camshaft 2 Position Slow Response. The DTC's may be intermittent and difficult to duplicate. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-018-07A > May > 07 > Engine Controls - MIL ON/DTC's P0016/P0017/P000A/P000B > Page 4352 **Verify that the oil pressure meets specifications as listed in DealerCONNECT > TechCONNECT. If the oil pressure does not meet specifications, the OCV will be unable to function properly. In this case, further diagnosis will be required to determine the cause of inappropriate oil pressure.** **If the Oil Pressure meets specifications, DTC's are present and cannot be duplicated, perform the Repair Procedure**. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: FLASH REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and/or 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 7.04 SP1 software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN® Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN® ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-018-07A > May > 07 > Engine Controls - MIL ON/DTC's P0016/P0017/P000A/P000B > Page 4353 4. Power ON the StarSCAN(R). 5. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. m. Turn the ignition switch to the OFF position for no less than 15 seconds. n. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING 5n OR 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. PM/MK Models equipped with a CVT must have the TCM reprogrammed as follows: 6. Using the StarSCAN(R) at the "Home screen: a. Select "ECU View" b. Touch the screen to highlight the 1CM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. 7. Is the TCM part number recorded in step 6e above, the same as the new p/n shown on the "Flash File List" screen? a. Yes >> No further action is necessary. Proceed to Step 9. b. No >> the TCM will require flash reprogramming, proceed to Step 8. 8. Flash reprogram the 1CM as follows: a. From the "Flash File List screen, select "Download to Scantool". Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-018-07A > May > 07 > Engine Controls - MIL ON/DTC's P0016/P0017/P000A/P000B > Page 4354 b. Select "Close" after the download is complete, then select "Back". c. Highlight the listed calibration. d. Select "Update Controller". Follow on screen instructions. e. When the update is complete, select "OK". f. Verify the part number at the top of the "Flash TCM screen has updated to the new part number. g. Turn the ignition switch to the OFF position for no less than 15 seconds. h. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the TCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list.** NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 9. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). 10. Following the procedures listed in DealerCONNECT > TechCONNECT, replace both intake and exhaust Oil Control Valves pn 04884695AA and 04884483AA. 11. Replace the engine oil and filter. POLICY: Reimbursable within the provisions of the warranty. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-018-07A > May > 07 > Engine Controls - MIL ON/DTC's P0016/P0017/P000A/P000B > Page 4355 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T - MIL ON Possible DTC P2004 NUMBER: 18-032-07 GROUP: Vehicle Performance DATE: May 16, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 7.04 SPI OR HIGHER FOR THIS BULLETIN. SUBJECT: Flash: MIL Illumination with DIG P2004 OVERVIEW: This bulletin involves selectively erasing and reprogramming the GPEC Powertrain Control Module (PCM) with new software and replacing the intake manifold as required. CAUTION: VEHICLES EQUIPPED WITH A CVT TRANSMISSION MUST HAVE THE TRANSMISSION CONTROL MODULE (TCM) CHECKED FOR THE LATEST SOFTWARE LEVEL WHENEVER THE PCM SOFTWARE IS UPGRADED. IF NEWER TCM SOFTWARE IS AVAILABLE, IT MUST BE INSTALLED. MODELS: 2007-2008 (JS) Avenger 2007 (JS) Sebring 2008 (J527) Sebring Convertible 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to models equipped with a 1.8L, 2.0L or 2.4L gasoline engine (Sales Code EBA, ECN or ED3) as follows: Flash portion applies to PM/MK models built through April 21, 2007 (MDH 0421 XX) and JS models built through May 15, 2007 (0515XX). The Intake Manifold Replacement portion applies to models built through March 22, 2007 (MDHO322XX). SYMPTOM/CONDITION: Some customers may experience MIL Illumination with no other symptoms. The condition may occur intermittently. Further investigation by the technician may find DTC P2004 - Intake Manifold Runner Control Stuck Open as the cause for MIL Illumination. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine Systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Perform the standard diagnostic procedures for DIG P2004. If the diagnostics do not lead to the failure, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 4360 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and/or 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 7.04 SPI software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service> StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options d. Select "ECU Flash e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 4361 j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. m. Turn the ignition switch to the OFF position for no less than 15 seconds. n. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING 5n OR 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. PM/MK Models equipped with a CVT must have the TCM reprogrammed as follows: 6. Using the StarSCAN(R) at the "Home screen": a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. 7. Is the TCM part number recorded in step 6e above, the same as the new pin shown on the "Flash File List" screen? a. Yes > No further action is necessary. Proceed to Step 9. b. No > the TCM will require flash reprogramming, proceed to Step 8. 8. Flash reprogram the TCM as follows: a. From the "Flash File List screen, select "Download to Scantool". b. Select "Close" after the download is complete, then select "Back". c. Highlight the listed calibration. d. Select "Update Controller". Follow on screen instructions. e. When the update is complete, select "OK". f. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. g. Turn the ignition switch to the OFF position for no less than 15 seconds. h. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP Sn and 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the TCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list.** Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 4362 NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig.1). 1. Vehicles built through March 22, 2007 will require a new Intake Manifold pn 04884495AF. Following the procedures listed in DealerCONNECT > TechCONNECT replace the intake manifold. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-033-06 > Nov > 06 > Engine Controls - MIL/Charge/Oil Lamps ON PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls MIL/Charge/Oil Lamps ON NUMBER: 18-033-06 GROUP: Vehicle Performance DATE:November 2, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES FOR StarSCAN. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 7.02 SPI OR HIGHER FOR THIS BULLETIN. SUBJECT: Flash: MIL Illumination/Generator Lamp Illumination/Oil Pressure Lamp Illumination/Driveability Improvements OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) and the Transmission Control Module (TCM) with new software and performing a memory reset to clear the adaptive memory of the PCM. CAUTION: VEHICLES (PM/MK) EQUIPPED WITH A CVT TRANSMISSION MUST HAVE THE TRANSMISSION CONTROL MODULE (TCM) CHECKED FOR THE LATEST SOFTWARE LEVEL WHENEVER THE PCM SOFTWARE IS UPGRADED. IF NEWER TCM SOFTWARE IS AVAILABLE, IT MUST BE INSTALLED. MODELS: 2007 (JS) Sebring 2007 (PM) Caliber 2007 (MK49) Compass NOTE: This bulletin applies to PM/MK models equipped with a 1.8L, 2.0L or 2.4L gasoline engine (Sales Code EBA, ECN or ED3) built before October 24, 2006 (MDH 1024XX). NOTE: This bulletin applies to JS models equipped with a 2.4L (Sales Code ED3) with the condition of momentary (1 to 2 second) oil indicator lamp illumination or flicker at idle and was originally addressed with RRT 06-048 Dated October 17, 2006. SYMPTOM/CONDITION: Some customers may experience MIL illumination, Intermittent Generator Lamp Illumination, Momentary (1 to 2 second) Oil indicator lamp illumination/flicker at idle or momentary delay returning to idle after clutch actuation. NOTE: Momentary oil lamp illumination at idle is due to oil pressure switch venting. This will NOT cause engine damage. This condition is most noticeable when the oil is hot, engine RPM is returned to idle and engine load from the power steering system is quickly applied. The technician may find one or more of the following DTC's or Symptoms: ^ P0139 - 02 Sensor 1/2 Slow Response. ^ P0700 - Transmission Control System (MIL REQUEST). This DTC is logged in PCM and when TCM is checked, DTC's are not present. ^ P063A - Generator Voltage Sense Circuit (Intermittent Generator Lamp Illumination). ^ Momentary (1 to 2 second) Oil Indicator Lamp Illumination or Flicker at Idle ^ Momentary Delay Returning to Idle when clutch is actuated (Vehicles Equipped with 2.4L Engine and Manual Transmission (Sales Code ED3 and DD7). DIAGNOSIS: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-033-06 > Nov > 06 > Engine Controls - MIL/Charge/Oil Lamps ON > Page 4367 Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If any of the above Symptom/Conditions are present, perform the Repair Procedure. If P0139 was present, verify exhaust system integrity after the reprogramming event by performing the drive cycle listed in TechCONNECT > Engine Electrical Diagnosis > Diagnosis and Testing > P0139, follow step 10. If P0139 reoccurs exhaust system leak checks and repairs will be required. Follow procedures listed in TechCONNECT > Engine Electrical Diagnosis > Diagnosis and Testing > Checking the Exhaust System for Leaks. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING **STEP 5n and/or 8h**. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 7.02 SPI software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN® diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN® for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-033-06 > Nov > 06 > Engine Controls - MIL/Charge/Oil Lamps ON > Page 4368 b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. m. Turn the ignition switch to the OFF position for no less than 15 seconds. n. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING 5n OR 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. PM/MK Models equipped with a CVT must have the TCM reprogrammed as follows: 6. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the 1CM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. 7. Is the TCM part number recorded in step 6e above, the same as the new pin shown on the "Flash File List" screen? a. Yes >> No further action is necessary. Proceed to Step # 9. b. No » the TCM will require flash reprogramming also, proceed to Step # 8. 8. Flash reprogram the TCM as follows: a. From the "Flash File List" screen, select "Download to Scantool". b. Select 'Close" after the download is complete, then select "Back". c. Highlight the listed calibration. d. Select "Update Controller". Follow on screen instructions. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-033-06 > Nov > 06 > Engine Controls - MIL/Charge/Oil Lamps ON > Page 4369 e. When the update is complete, select "OK". f. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. g. Turn the ignition switch to the OFF position for no less than 15 seconds. h. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the TCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. ** 9. Reset the adaptive memory of the PCM with the StarSCAN(R). Using the StarSCAN(R) at the "Home Screen": a. Select "ECU View". b. Highlight "PCM" in the list of modules; c. Select "Misc. Functions". d. Select "Reset Memory". e. Select "All Adaptive Memory". NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-033-06 > Nov > 06 > Engine Controls - MIL/Charge/Oil Lamps ON > Page 4370 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-020-06A > Sep > 06 > Engine Controls - Spark Knock When Warm/DTC P2173/P0452 PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Spark Knock When Warm/DTC P2173/P0452 NUMBER: 18-020-06 REV. A GROUP: Vehicle Performance DATE: September 16, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-020-06 DATED JUNE 13, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES AN ADDITIONAL MODEL, REVISED SOFTWARE, CLEAN DATE, AND REVISED SYMPTOM/CONDITIONS, REPAIR PROCEDURES AND LABOR OPERATION NUMBERS THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES FOR StarSCAN. SUBJECT: Flash: Warm Weather Spark Knock and/or DIG P2173 **and/or P0452** OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) **and if necessary, the Transmission Control Module (TCM)** with new software and performing a memory reset to clear the adaptive memory of the PCM. MODELS: 2007 (PM) Caliber **2007 (MK49) Compass** NOTE: This bulletin applies to models equipped with a 2.0L or 2.4L gasoline engine and CVT transmission (sales code ECN or ED3 with DAV) built on or after May 11, 2006 (MDH 0511Xx) through and including August 16, 2006 (MDH 0816XX). SYMPTOM/CONDITION: Some customers may experience Spark Knock in warm ambient conditions (16°C (60°F) or higher). The technician may find one or more of the following DTC's. ^ P2173 - High Airflow/Vacuum Leak Detected (Slow Accumulation) may be found in the PCM. This DTC may occur when a vehicle is driven from a higher altitude to a lower altitude (1372 meter (4500 foot) change). ^ **P0452-Evap Pressure Switch Stuck Closed** DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the customer describes a Spark Knock condition, or the technician finds either DTC, perform the Repair Procedure. NOTE: If service bulletin 18-020-06 has been performed and the Symptom/Condition is still present, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-020-06A > Sep > 06 > Engine Controls - Spark Knock When Warm/DTC P2173/P0452 > Page 4375 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING **STEP 5n and 8h**. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 7.02 software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-020-06A > Sep > 06 > Engine Controls - Spark Knock When Warm/DTC P2173/P0452 > Page 4376 j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. m. Turn the ignition switch to the OFF position for no less than 15 seconds. n. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING 5n AND 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 6. **Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. 7. Is the TCM part number recorded in step 6e above, the same as the new p/n shown on the "Flash File List" screen? a. Yes >> No further action is necessary. Proceed to Step # 9. b. No >> the TCM will require flash reprogramming also, proceed to Step # 8. 8. Flash reprogram the TCM as follows: a. From the "Flash File List" screen, select "Download to Scantool". b. Select "Close" after the download is complete, then select "Back". c. Highlight the listed calibration. d. Select "Update Controller". Follow on screen instructions. e. When the update is complete, select "OK". f. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. g. Turn the ignition switch to the OFF position for no less than 15 seconds. h. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the TCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. ** 9. Reset the adaptive memory of the PCM with the StarSCAN®. This function is found under Miscellaneous Functions and is called Reset Memory. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-020-06A > Sep > 06 > Engine Controls - Spark Knock When Warm/DTC P2173/P0452 > Page 4377 Select All Adaptive Memory. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-001-06A > Jul > 06 > Engine Controls - Flash Reprogramming Abort Recovery PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Flash Reprogramming Abort Recovery NUMBER: 18-001-06 REV. A GROUP: Vehicle Performance DATE: July 12, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-001-06, DATED JANUARY II, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, YEARS AND A REVISED DISCUSSION ABOUT ABORTED FLASH REPROGRAMMING RECOVERY. SUBJECT: StarSCAN(R)/StarMOBILE(TM) Abort Recovery Procedures OVERVIEW: This Bulletin provides guidelines to minimize flash reprogramming problems and recovery procedure information for failed flash attempts. MODELS: **2007 (DC) Ram Cab & Chassis** 2006 - **2007** (DR/DH/D1) Ram Truck 2004 - **2007** (HB/HG) Durango/Aspen 2007 (JK) Wrangler **2007 (JS) Sebring** **2007 (KA) Nitro** 2006 - **2007** (KJ) Liberty/Cherokee 2005 - **2007** (LX/LE) 300/Magnum/Charger **2007 (MK) Compass** 2005 - **2007** (ND) Dakota **2007 (PM) Caliber** 2006 - **2007* (PT) PT Cruiser 2005 - **2007** (WK/WH) Grand Cherokee 2006 - **2007** (XK/XH) Commander DISCUSSION: NOTE: Many of the reasons a flash reprogramming procedure may not complete are documented in this service bulletin. Occasionally a flash update procedure may not complete properly and/or the diagnostic equipment may lock up or become disconnected during the procedure. Flash Reprogramming is a "CRITICAL PROCESS"; an error may result in a no-start/failed control module. Most modules, encountering an interruption or failure while reprogramming, are recoverable. Replacing a module that is recoverable is not covered under the provisions of the warranty. This service bulletin covers items that may cause this condition, a process to restart the flash procedure, and miscellaneous information that will help prevent unnecessary replacement of control modules. GENERAL: Flash Reprogramming is only authorized when programming a generic module or by a specific SERVICE ACTION (Service Bulletin/Recall/Rapid Response Transmittal/Advance Service Information). CAUTION: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-001-06A > Jul > 06 > Engine Controls - Flash Reprogramming Abort Recovery > Page 4382 When updating a module because of a Service Action, it is important to follow the steps outlined in the Repair Procedure section of the Service Action. Procedures may differ depending on the module that is being reprogrammed. Review the entire Service Action prior to performing a flash reprogramming update. Often other parts may need to be serviced, replaced, or tested, prior to flash reprogramming, and ARE REQUIRED as part of completing the Service Action. COMMON CAUSES OF FLASH REPROGRAMMING ERRORS Interruptions, voltage problems, a variety of other outside interactions, and failure to follow the steps outlined in the Service Action can potentially interfere with the process. This document seeks to provide information to minimize problems associated with module flash reprogramming. SOFTWARE VERSIONS MUST BE CURRENT Before attempting a flash reprogramming session, make sure you have the most current software installed in the scan tool (StarSCAN(R)/StarMOBILE(TM)). Refer to the current software release information available in TechCONNECT, under: Service Info > StarSCAN(R) and StarMOBILE(TM) Tools > Latest News > Select the most recent release number. The technician will be able to see the applicable version numbers. Often, because of multiple StarSCAN(R)/StarMOBILE(TM)s in the shop, not all devices will get updated in a timely manner. The installed StarSCAN(R)/StarMOBILE(TM) software version and scan tool operating system version, (Fig. 2), can be verified from the "Home" screen as follows: StarMOBILE Desktop Client ^ Select "Tool Menu". ^ Select "Version Information" Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-001-06A > Jul > 06 > Engine Controls - Flash Reprogramming Abort Recovery > Page 4383 StarSCAN ^ Select "Show Shortcuts" ^ Select "Tool Menu". ^ Select "Version Information" Typical Tool Menu (Fig. 1) NOTE: The StarSCAN also displays the version number on the right side of the blue header at the top of each screen. NOTE: To read the version on the StarMOBILE(TM), it must be connected and the application running or the user will receive "N/A" for the "System" value. GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS Consider ALL cables to be wear items. It is a good practice to have dedicated cables devoted to "Flash ONLY". Always have a spare StarSCAN(R) CH9404 (vehicle) cable available. Always have a spare StarMOBILE(TM) CH9804 (vehicle) cable available (blue cable end). Diagnosing vehicle cable problems Inspect vehicle cable connectors for potential problems that might cause communication interruptions. Use the information available on DealerCONNECT under: ^ eSupport (above the "Marketing" tab) ^ Under "Knowledge Center" - select "Find Answers" ^ In the "Enter link, error message, or topic" area, type "561" ^ In the "Search By" area, select "Answer ID" ^ At the next screen, select the "StarSCAN Flash Lockup.pdf" link to access the information to diagnose suspect vehicle cable continuity. FLASH REPROGRAMMING PROBLEM PREVENTION ^ Follow the steps outlined in the Service Action. ^ Pay attention to the screen prompts displayed during the flash process. ^ Replace worn cables. ^ Verify the vehicle is equipped with a known good battery. ^ Ensure the battery charger charging rate provides approximately 13.2 - 13.8 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. **ABORTED FLASH REPROGRAMMING RECOVERY** ** The following steps may help recover a non-responsive module when the flash process is aborted or interrupted. 1. When the Flash ECU screen displays an Error Message, select OK. 2. Turn the ignition to "off" and power down the StarSCAN(R). 3. Turn the vehicle ignition to the "On" position. 4. Power on the StarSCAN®. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-001-06A > Jul > 06 > Engine Controls - Flash Reprogramming Abort Recovery > Page 4384 NOTE: If the technician was flashing a PCM, the tool may display "Unknown VIN". Disregard this. 5. Select (ECU) View. 6. Highlight the ECU that was being flashed. NOTE: The module may appear to be non-responsive. Highlight the module anyway. 7. Select More Options 8. Select ECU Flash 9. If the "Flash ECU" screen displays "Resident flash files for Part # XXXXX", the module should be recoverable. If the screen displays "No resident flash files found" the module is not recoverable. Does the Flash ECU screen display "No resident flash files found?" a. Yes >> The module must be replaced. b. No >> proceed to Step # 10. 10. Is a calibration file displayed on the StarSCAN(R)? a. Yes >> proceed to Step # 11. b. No >> Select "Browse For New File" and follow on screen instructions. Highlight the calibration that was previously chosen. Select "Download to Scantool". When the file is downloaded to the scantool, select "Back" and proceed to Step # 11. 11. Highlight the appropriate calibration. 12. Select "Update Controller" and follow the on screen instructions. 13. When the flash is complete, verify the "Resident flash file part number" matches the 'New PIN" of the appropriate calibration. 14. Proceed with the steps listed in the Service Bulletin to complete the service action.** NOTE: If after following the steps above, you are still having issues performing the flash reprogramming procedure using a specific StarSCAN(R)/StarMOBILE(R) it is suggested to contact SPX/Miller Special Tools for service. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B Technical Service Bulletin # 18-019-06 Date: 060607 A/T Controls - MIL ON/DTC's P0602/P167A or P161B NUMBER: 18-019-06 GROUP: Vehicle Performance DATE: June 7, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: Flash: MIL Illumination - DTC's P0602, P167A, or P161B OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (TCM) with new software and the Powertrain Control Module (PCM) with new software. WARNING: BOTH CONTROLLERS (TCM AND PCM) MUST BE REPROGRAMMED. THIS UPDATE MUST BE COMPLETED AS A COORDINATED CHANGE. IF THE PCM IS NOT UPDATED, MIL ILLUMINATION CAN OCCUR AND DTC U1424 (IMPLAUSIBLE ENGINE TORQUE MESSAGE RECEIVED) WILL BE RECORDED IN THE TCM. MODELS: 2007 (PM) Caliber NOTE: This bulletin applies to vehicles equipped with a Continuously Variable Transmission (CVT), (sales code DAV), built on or before June 1, 2006 (MDH 0601XX). SYMPTOM/CONDITION: The customer may experience Malfunction Indicator Lamp (MIL) illumination. The technician may find the following Diagnostic Trouble Codes (DTC's) in the TCM: ^ P0602-Control Module Programming Error/Not Programmed ^ P167A-Calibration Mismatch ^ P161B-Battery Disconnect / TCM Internal DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes MIL Illumination and the technician finds any of the DTC's listed above, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B > Page 4389 SPECIAL TOOLS / EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. TCM - Repair Procedure - Using the Internet to Retrieve the Flash File NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 6.06 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old TCM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B > Page 4390 b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". I. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. NOTE: Due to the TCM/PCM programming procedure, a DTC may be set in other modules (BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTC's". Press "Clear All Stored DTC's" if there are any DTC's shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 6. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). PCM Repair Procedure - Using the Internet to Retrieve the Flash File CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 6.06 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B > Page 4391 StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the PCM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. m. Turn the ignition switch to the OFF position for no less than 15 seconds. n. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 6. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-015-06 > Apr > 06 > Engine Controls - MIL ON/DTC's P0071/P0139/P060F PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0071/P0139/P060F NUMBER: 18-015-06 GROUP: Vehicle Performance DATE: April 12, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES FOR StarSCAN. SUBJECT: Flash: MIL Illumination P0071, P0139, PO6OF, Immobilizer Secret Key to WCM Transfer, and DTC P0522 OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2007 (PM) Caliber NOTE: This bulletin applies to models equipped with a 1.8L, 2.0L, 2.4L gasoline engine (sales code EBA, ECN, or ED3) built on or before April 10, 2006 (MDH 0410XX). SYMPTOM/CONDITION: The Malfunction Indicator Lamp (MIL) may illuminate due to one or more of the following DTC's. ^ P0071 - AMBIENT AIR TEMPERATURE SENSOR PERFORMANCE ^ P0139 - 02 SENSOR 1/2 SLOW RESPONSE ^ P060F - ETC LEVEL 2 ECT PERFORMANCE In addition to MIL illumination with the above DTC's, changes have been made to address an error in DTC P0522 - Engine Oil Pressure Switch Circuit Low and writing the secret key to the WCM (Wireless Control Module) when a WCM is replaced. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above DTC's have been recorded or if Immobilizer keys cannot be registered after WCM replacement, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-015-06 > Apr > 06 > Engine Controls - MIL ON/DTC's P0071/P0139/P060F > Page 4396 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 6.05_5P4 level software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the appropriate ECU in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-015-06 > Apr > 06 > Engine Controls - MIL ON/DTC's P0071/P0139/P060F > Page 4397 i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. m. Turn the ignition switch to the OFF position for no less than 15 seconds. n. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the ECU programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 6. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-001-06A > Jul > 06 > Engine Controls - Flash Reprogramming Abort Recovery > Page 4403 When updating a module because of a Service Action, it is important to follow the steps outlined in the Repair Procedure section of the Service Action. Procedures may differ depending on the module that is being reprogrammed. Review the entire Service Action prior to performing a flash reprogramming update. Often other parts may need to be serviced, replaced, or tested, prior to flash reprogramming, and ARE REQUIRED as part of completing the Service Action. COMMON CAUSES OF FLASH REPROGRAMMING ERRORS Interruptions, voltage problems, a variety of other outside interactions, and failure to follow the steps outlined in the Service Action can potentially interfere with the process. This document seeks to provide information to minimize problems associated with module flash reprogramming. SOFTWARE VERSIONS MUST BE CURRENT Before attempting a flash reprogramming session, make sure you have the most current software installed in the scan tool (StarSCAN(R)/StarMOBILE(TM)). Refer to the current software release information available in TechCONNECT, under: Service Info > StarSCAN(R) and StarMOBILE(TM) Tools > Latest News > Select the most recent release number. The technician will be able to see the applicable version numbers. Often, because of multiple StarSCAN(R)/StarMOBILE(TM)s in the shop, not all devices will get updated in a timely manner. The installed StarSCAN(R)/StarMOBILE(TM) software version and scan tool operating system version, (Fig. 2), can be verified from the "Home" screen as follows: StarMOBILE Desktop Client ^ Select "Tool Menu". ^ Select "Version Information" Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-001-06A > Jul > 06 > Engine Controls - Flash Reprogramming Abort Recovery > Page 4404 StarSCAN ^ Select "Show Shortcuts" ^ Select "Tool Menu". ^ Select "Version Information" Typical Tool Menu (Fig. 1) NOTE: The StarSCAN also displays the version number on the right side of the blue header at the top of each screen. NOTE: To read the version on the StarMOBILE(TM), it must be connected and the application running or the user will receive "N/A" for the "System" value. GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS Consider ALL cables to be wear items. It is a good practice to have dedicated cables devoted to "Flash ONLY". Always have a spare StarSCAN(R) CH9404 (vehicle) cable available. Always have a spare StarMOBILE(TM) CH9804 (vehicle) cable available (blue cable end). Diagnosing vehicle cable problems Inspect vehicle cable connectors for potential problems that might cause communication interruptions. Use the information available on DealerCONNECT under: ^ eSupport (above the "Marketing" tab) ^ Under "Knowledge Center" - select "Find Answers" ^ In the "Enter link, error message, or topic" area, type "561" ^ In the "Search By" area, select "Answer ID" ^ At the next screen, select the "StarSCAN Flash Lockup.pdf" link to access the information to diagnose suspect vehicle cable continuity. FLASH REPROGRAMMING PROBLEM PREVENTION ^ Follow the steps outlined in the Service Action. ^ Pay attention to the screen prompts displayed during the flash process. ^ Replace worn cables. ^ Verify the vehicle is equipped with a known good battery. ^ Ensure the battery charger charging rate provides approximately 13.2 - 13.8 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. **ABORTED FLASH REPROGRAMMING RECOVERY** ** The following steps may help recover a non-responsive module when the flash process is aborted or interrupted. 1. When the Flash ECU screen displays an Error Message, select OK. 2. Turn the ignition to "off" and power down the StarSCAN(R). 3. Turn the vehicle ignition to the "On" position. 4. Power on the StarSCAN®. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-001-06A > Jul > 06 > Engine Controls - Flash Reprogramming Abort Recovery > Page 4405 NOTE: If the technician was flashing a PCM, the tool may display "Unknown VIN". Disregard this. 5. Select (ECU) View. 6. Highlight the ECU that was being flashed. NOTE: The module may appear to be non-responsive. Highlight the module anyway. 7. Select More Options 8. Select ECU Flash 9. If the "Flash ECU" screen displays "Resident flash files for Part # XXXXX", the module should be recoverable. If the screen displays "No resident flash files found" the module is not recoverable. Does the Flash ECU screen display "No resident flash files found?" a. Yes >> The module must be replaced. b. No >> proceed to Step # 10. 10. Is a calibration file displayed on the StarSCAN(R)? a. Yes >> proceed to Step # 11. b. No >> Select "Browse For New File" and follow on screen instructions. Highlight the calibration that was previously chosen. Select "Download to Scantool". When the file is downloaded to the scantool, select "Back" and proceed to Step # 11. 11. Highlight the appropriate calibration. 12. Select "Update Controller" and follow the on screen instructions. 13. When the flash is complete, verify the "Resident flash file part number" matches the 'New PIN" of the appropriate calibration. 14. Proceed with the steps listed in the Service Bulletin to complete the service action.** NOTE: If after following the steps above, you are still having issues performing the flash reprogramming procedure using a specific StarSCAN(R)/StarMOBILE(R) it is suggested to contact SPX/Miller Special Tools for service. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > F29 > Jul > 06 > Recall - Software Update for OBD Monitoring Technical Service Bulletin # F29 Date: 060701 Recall - Software Update for OBD Monitoring July 2006 Dealer Service Instructions for: Emissions Recall F29 Reprogram PCM OBD Thermostat Monitor Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Service Bulletin (TSB) # 18-020-06 has been cancelled for vehicles built through May 11, 2006. Models 2007 (PM) Dodge Caliber NOTE: This recall applies only to the above vehicles built through May 11, 2006 (MDH 051106). IMPORTANT: Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Powertrain Control Module (PCM) on about 29,600 on the above vehicles was inadvertently programmed with diagnostic software that is unable to detect an engine thermostat malfunction. As a result, the Malfunction Indicator Lamp will not illuminate if the thermostat fails. Repair The PCM must be reprogrammed (flashed). Parts Information Each dealer to whom vehicles in the recall were assigned will receive enough Authorized Modifications Labels to service about 20% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the labels shown. Special Tools Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > F29 > Jul > 06 > Recall - Software Update for OBD Monitoring > Page 4410 The existing special tools shown may be required to perform this repair. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive a copy of this dealer recall notification letter by mail. Two additional copies will be sent through the DCMMS. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > F29 > Jul > 06 > Recall - Software Update for OBD Monitoring > Page 4411 Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure Reprogram the Powertrain Control Module NOTE: This procedure must be performed with release 7.01 or later. To update your StarSCAN(R) diagnostic tool via the internet, the StarSCAN software must be at version 7.01 and properly configured to work with your dealership's network. 1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View" b. Touch the screen to highlight "PCM" in the list of modules. c. Select "More Options". d. Select "PCM Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "ECU Overview" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date and no further action is required. If the part number is different, continue with Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back" f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404 StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404 StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > F29 > Jul > 06 > Recall - Software Update for OBD Monitoring > Page 4412 a. Select "ECU View" b. Touch the screen to highlight "PCM" in the list of modules. c. Select "More Options". d. Select "PCM Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. NOTE: Due to the PCM programming procedure, a Diagnostic Trouble Code (DTC) may be set in other modules (ABS, TCM, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. B. Install the Authorized Modifications Label: 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. C. Complete Proof of Correction Form for California Residents: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > F29 > Jul > 06 > Recall - Software Update for OBD Monitoring > Page 4413 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > F29 > Jul > 06 > Recall - Software Update for OBD Monitoring > Page 4414 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor Control Module: Technical Service Bulletins Engine Controls - MIL On/DTC P0116/ECT Sensor NUMBER: 18-039-06 GROUP: Vehicle Performance DATE: December 6, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES FOR StarSCAN. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 7.02 SP2 OR HIGHER FOR THIS BULLETIN. SUBJECT: Flash: MIL Illumination DTC P0116 - Engine Coolant Temperature Sensor Performance OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) and the Transmission Control Module (1CM) with new software. CAUTION: VEHICLES EQUIPPED WITH A CVT TRANSMISSION MUST HAVE THE TRANSMISSION CONTROL MODULE (TCM) CHECKED FOR THE LATEST SOFTWARE LEVEL WHENEVER THE PCM SOFTWARE IS UPGRADED. IF NEWER TCM SOFTWARE IS AVAILABLE, IT MUST BE INSTALLED. MODELS: 2007 (PM) Caliber 2007 (MK49) Compass NOTE: This bulletin applies to PM/MK models equipped with a 1.8L, 2.0L or 2.4L gasoline engine (Sales Code EBA, ECN or ED3) and block heater (Sales Code NHK) built before November 20, 2006 (MDH 1120XX). NOTE: If an aftermarket or MOPAR accessory block heater is installed, the same conditions may apply. SYMPTOM/CONDITION: Some customers may experience MIL illumination after using the block heater. No other symptoms will be experienced. The technician may find the following DTC's: ^ P0116 - ENGINE COOLANT TEMPERATURE SENSOR PERFORMANCE DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If MIL illumination with DTC P0116 is present, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 4421 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING **STEP 5n and/or 8h**. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 7.02 SP2 software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. PM/MK Models equipped with a CVT must have the TCM reprogrammed as follows: 6. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. 7. Is the TCM part number recorded in step 6e above, the same as the new p/n shown on the "Flash File List" screen? a. Yes >> No further action is necessary. Proceed to Step 9. b. No >> the TCM will require flash reprogramming, proceed to Step 8. 8. Flash reprogram the TCM as follows: a. From the "Flash File List" screen, select "Download to Scantool". b. Select "Close" after the download is complete, then select "Back". c. Highlight the listed calibration. d. Select "Update Controller". Follow on screen instructions. e. When the update is complete, select "OK". f. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. g. Turn the ignition switch to the OFF position for no less than 15 seconds. h. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 4422 CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the TCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. ** NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 9. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - A/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4428 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - A/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4433 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor Control Module: Technical Service Bulletins Engine Controls - MIL On/DTC P0116/ECT Sensor NUMBER: 18-039-06 GROUP: Vehicle Performance DATE: December 6, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES FOR StarSCAN. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 7.02 SP2 OR HIGHER FOR THIS BULLETIN. SUBJECT: Flash: MIL Illumination DTC P0116 - Engine Coolant Temperature Sensor Performance OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) and the Transmission Control Module (1CM) with new software. CAUTION: VEHICLES EQUIPPED WITH A CVT TRANSMISSION MUST HAVE THE TRANSMISSION CONTROL MODULE (TCM) CHECKED FOR THE LATEST SOFTWARE LEVEL WHENEVER THE PCM SOFTWARE IS UPGRADED. IF NEWER TCM SOFTWARE IS AVAILABLE, IT MUST BE INSTALLED. MODELS: 2007 (PM) Caliber 2007 (MK49) Compass NOTE: This bulletin applies to PM/MK models equipped with a 1.8L, 2.0L or 2.4L gasoline engine (Sales Code EBA, ECN or ED3) and block heater (Sales Code NHK) built before November 20, 2006 (MDH 1120XX). NOTE: If an aftermarket or MOPAR accessory block heater is installed, the same conditions may apply. SYMPTOM/CONDITION: Some customers may experience MIL illumination after using the block heater. No other symptoms will be experienced. The technician may find the following DTC's: ^ P0116 - ENGINE COOLANT TEMPERATURE SENSOR PERFORMANCE DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If MIL illumination with DTC P0116 is present, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 4439 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING **STEP 5n and/or 8h**. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 7.02 SP2 software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. PM/MK Models equipped with a CVT must have the TCM reprogrammed as follows: 6. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. 7. Is the TCM part number recorded in step 6e above, the same as the new p/n shown on the "Flash File List" screen? a. Yes >> No further action is necessary. Proceed to Step 9. b. No >> the TCM will require flash reprogramming, proceed to Step 8. 8. Flash reprogram the TCM as follows: a. From the "Flash File List" screen, select "Download to Scantool". b. Select "Close" after the download is complete, then select "Back". c. Highlight the listed calibration. d. Select "Update Controller". Follow on screen instructions. e. When the update is complete, select "OK". f. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. g. Turn the ignition switch to the OFF position for no less than 15 seconds. h. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 4440 CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the TCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. ** NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 9. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Description and Operation > Description Clutch Disc: Description and Operation Description DESCRIPTION The modular clutch assembly (1) is located between the engine and manual transaxle in the transaxle bellhousing, and is responsible for transmitting engine power to the transaxle. The modular clutch is an assembly which incorporates a self-adjusting design and consists of the following components: - Flywheel - Clutch Disc - Pressure Plate - Diaphragm Spring - Adjusting Ring - Sensor - Cover Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Description and Operation > Description > Page 4446 Clutch Disc: Description and Operation Operation OPERATION The modular clutch assembly is designed to transmit power from the engine to the manual transaxle. This is accomplished by the friction and clamping force generated when the spring loaded pressure plate locks the clutch disc to the flywheel. The clutch disc, which is splined to the transaxle input shaft, transmits power until the center of the diaphragm spring is depressed, and the clamp force is removed from the disc. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Description and Operation > Description > Page 4447 The self-adjusting feature of this clutch assembly relies on the sensor ring (4) and the adjuster ring (5), which works its way around a ramped clutch cover (2), taking up clearance as the clutch disc wears and maintaining diaphragm spring force throughout the life of the clutch. The primary benefits of this design are reduced pedal effort, constant release load over clutch life, and extended clutch life. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Clutch Disc and Pressure Plate Clutch Disc: Service and Repair Clutch Disc and Pressure Plate Removal REMOVAL DIESEL 1. Remove transaxle assembly. 2. Mark position of pressure plate (3) on flywheel (1) with paint or scribe for assembly reference. 3. Loosen and remove six pressure plate-to-flywheel bolts. Remove pressure plate (3) and clutch disc (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Clutch Disc and Pressure Plate > Page 4450 4. Remove eight flywheel-to-crankshaft bolts and remove flywheel assembly (1). GAS 1. Remove transaxle assembly. 2. Remove the modular clutch assembly (1). Installation INSTALLATION DIESEL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Clutch Disc and Pressure Plate > Page 4451 1. Inspect clutch release bearing and lever for excessive wear and replace as necessary. The release bearing is integral to the Concentric Slave Cylinder (CSC). 2. Clean the surfaces of the flywheel (1) and pressure plate to make certain that all oil, grease, and rust have been removed. 3. Verify the crankshaft mounting flange is free of debris, oil, grease, etc. Position the flywheel (1) onto the engine crankshaft. 4. Install flywheel to crankshaft. Install eight (8) flywheel-to-crankshaft bolts and tighten to 45 Nm (33 ft. lbs.) plus an additional 1/4 turn (90 degrees). 5. Apply a very light coating of grease to the splines in the clutch disc hub. 6. Position the clutch disc (2) to the flywheel (1). Make sure the side marked "FLYWHEEL SIDE" faces the flywheel (1). 7. Install the clutch pressure plate (1) to the flywheel and clutch disc. Finger tighten the six pressure plate-to-flywheel bolts. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Clutch Disc and Pressure Plate > Page 4452 8. Use Clutch Alignment Tool 6724 (3) to position the clutch disc (2) to the center of the flywheel (1). 9. Tighten pressure plate bolts (2) evenly and in rotation a few threads at a time The bolts must be tightened evenly and to specified torque to avoid distorting the pressure plate. 10. Using a "criss-cross" pattern, torque pressure plate bolts (2) to 31 Nm (23 ft. lbs.). Remove the clutch disc alignment tool. 11. Apply light coat of MOPAR(R) High Temperature Bearing Grease or equivalent to clutch disc hub and splines of transmission input shaft. CAUTION: Do not over lubricate shaft splines. This will result in grease contamination of disc. 12. Install transaxle. GAS Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Clutch Disc and Pressure Plate > Page 4453 1. Install new modular clutch assembly onto input shaft of transmission. 2. Install the transmission. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Clutch Disc and Pressure Plate > Page 4454 Clutch Disc: Service and Repair Modular Clutch Removal REMOVAL 1. Remove transaxle (3) from vehicle. 2. Remove modular clutch assembly (1) from transaxle input shaft. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Clutch Disc and Pressure Plate > Page 4455 3. Disassemble modular clutch assembly (If individual parts are available). Remove six pressure plate-to-flywheel bolts (1). Remove pressure plate (2) and disc from flywheel. Inspection INSPECTION Fluid contamination is a frequent cause of clutch malfunctions. Oil, grease, water, or other fluids on the clutch contact surfaces will cause faulty operation. During inspection, note if any components are contaminated. Look for evidence of oil, grease, or water/road splash on clutch components. OIL CONTAMINATION Oil contamination indicates a leak at the rear main seal and/or transaxle input shaft. Oil leaks produce a residue of oil on the transaxle housing interior, clutch cover and flywheel. Heat buildup caused by slippage can bake the oil residue onto the components. This glaze-like residue ranges in color from amber to black. GREASE CONTAMINATION Grease contamination is usually a product of over-lubrication. During clutch service, apply only a small amount of grease to the input shaft splines. Excess grease may be thrown off during operation, contaminating the disc. ROAD SPLASH/WATER CONTAMINATION Road splash contamination is usually caused by driving the vehicle through deep water puddles. Water can be forced into the clutch housing, causing clutch components to become contaminated. Facing of disc will absorb moisture and bond to the flywheel and/or, pressure plate, if vehicle is allowed to stand for some time before use. If this condition occurs, replacement of clutch assembly may be required. Drive the vehicle until normal clutch operating temperature has been obtained. This will dry off disc assembly, pressure plate, and flywheel. Installation INSTALLATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Clutch Disc and Pressure Plate > Page 4456 1. Install clutch module onto input shaft. 2. Install transaxle into vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Clutch Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4462 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Technical Service Bulletins > Page 4463 Clutch Fluid: Specifications Clutch Fluid Type Mopar DOT 3, SAE J1703 should be used. If DOT 3, SAE J1703 brake fluid is not available, then DOT 4 is acceptable. Use only recommended brake fluids or equivalent. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Clutch Master Cylinder: > 06-006-07 > Dec > 07 > M/T - Clutch Pedal Squeaks When Operated Clutch Master Cylinder: Customer Interest M/T - Clutch Pedal Squeaks When Operated NUMBER: 06-006-07 GROUP: Clutch DATE: December 5, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 06-001-06, DATED OCTOBER 17, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF CLEAN POINTS. SUBJECT: Clutch Pedal Squeak OVERVIEW: This bulletin involves lubricating the clutch master cylinder pushrod ball socket (attachment at clutch pedal arm). MODELS: 2007 (JS) Sebring 2007 (PM) Caliber 2007 (MK49) Compass NOTE: **This information applies to models equipped with a T-355 or BG6 Manual Transmission (Sales Code DD7 or DEF) built prior to February 8, 2007 (MDH0208XX)**. SYMPTOM/CONDITION: A squeak sound may be heard when applying or releasing the clutch pedal. This may be more noticeable in cold temperatures. DIAGNOSIS: If the customer describes a squeak sound when applying the clutch pedal, perform the Repair Procedure PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove the lower instrument panel bezel. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Clutch Master Cylinder: > 06-006-07 > Dec > 07 > M/T - Clutch Pedal Squeaks When Operated > Page 4472 2. Disconnect clutch master cylinder pushrod from clutch pedal arm (Fig. 1). 3. Lubricate the pushrod ball socket with a small amount of Silicone Grease pn 05019061AA. 4. Connect clutch master cylinder rod to clutch pedal pin. An audible "click" should be heard. 5. Install lower instrument panel bezel. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Clutch Master Cylinder: > 06-006-07 > Dec > 07 > M/T - Clutch Pedal Squeaks When Operated > Page 4473 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Master Cylinder: > 06-006-07 > Dec > 07 > M/T - Clutch Pedal Squeaks When Operated Clutch Master Cylinder: All Technical Service Bulletins M/T - Clutch Pedal Squeaks When Operated NUMBER: 06-006-07 GROUP: Clutch DATE: December 5, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 06-001-06, DATED OCTOBER 17, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF CLEAN POINTS. SUBJECT: Clutch Pedal Squeak OVERVIEW: This bulletin involves lubricating the clutch master cylinder pushrod ball socket (attachment at clutch pedal arm). MODELS: 2007 (JS) Sebring 2007 (PM) Caliber 2007 (MK49) Compass NOTE: **This information applies to models equipped with a T-355 or BG6 Manual Transmission (Sales Code DD7 or DEF) built prior to February 8, 2007 (MDH0208XX)**. SYMPTOM/CONDITION: A squeak sound may be heard when applying or releasing the clutch pedal. This may be more noticeable in cold temperatures. DIAGNOSIS: If the customer describes a squeak sound when applying the clutch pedal, perform the Repair Procedure PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove the lower instrument panel bezel. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Master Cylinder: > 06-006-07 > Dec > 07 > M/T - Clutch Pedal Squeaks When Operated > Page 4479 2. Disconnect clutch master cylinder pushrod from clutch pedal arm (Fig. 1). 3. Lubricate the pushrod ball socket with a small amount of Silicone Grease pn 05019061AA. 4. Connect clutch master cylinder rod to clutch pedal pin. An audible "click" should be heard. 5. Install lower instrument panel bezel. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Master Cylinder: > 06-006-07 > Dec > 07 > M/T - Clutch Pedal Squeaks When Operated > Page 4480 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Description and Operation > Description - LHD Clutch Master Cylinder: Description and Operation Description - LHD DESCRIPTION NOTE: The clutch master cylinder/hydraulic release system does not have its own reservoir. This system is supplied fluid from the brake master cylinder reservoir. The clutch master cylinder (1) mounts to the clutch pedal and consists of a push rod, a piston and cylinder housing, an interconnecting hydraulic tube and a supply hose which connects to the brake master cylinder reservoir (1) for fluid supply. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Description and Operation > Description - LHD > Page 4483 Clutch Master Cylinder: Description and Operation Operation - LHD OPERATION When the clutch pedal is depressed, the push rod moves the piston in the master cylinder (2), displacing fluid through the hydraulic line and into the release bearing. The release bearing is forced into the fingers of the clutch diaphragm springs. As the fingers move, they release the clamping pressure on the clutch disc between the clutch pressure plate and the flywheel. The clutch becomes disengaged as this pressure is released. When the clutch pedal is released, the system hydraulic pressure is released. This allows the force of the clutch diaphragm springs to return to their original position, re-clamping the clutch disc between the flywheel and the clutch pressure plate. Also, the release bearing and lever are forced to return, which reverses the movement of the hydraulic system and returns the pedal to its original position against the up-stop. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Removal - LHD Clutch Master Cylinder: Service and Repair Removal - LHD REMOVAL 1. Remove the engine cover. 2. Remove air cleaner assembly (1). 3. Disconnect battery negative cable (2). 4. Remove lower instrument panel bezel. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Removal - LHD > Page 4486 5. Disconnect the pushrod (3) at the clutch pedal. 6. Disconnect hydraulic supply tube at clutch master cylinder by pulling retaining clip (5) then pulling out on tube. To completely drain clutch master cylinder and tubing, remove brake master cylinder cap band drain fluid into suitable container. 7. Disconnect clutch master cylinder supply line from brake master cylinder reservoir (1). Cap off or collect fluid spillage from reservoir port. CAUTION: Use care when removing clutch master cylinder from engine compartment. Aggressive handling can result in a damaged hydraulic tube and improper clutch release operation upon reassembly. CAUTION: Brake fluid will damage painted surfaces. If brake fluid is spilled on any painted surfaces, wash it off immediately with water. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Removal - LHD > Page 4487 8. Remove master cylinder assembly (1) from mounting position by turning 1/4 turn and carefully work hydraulic pipe from out of left rail retainer and engine compartment. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Removal - LHD > Page 4488 Clutch Master Cylinder: Service and Repair Installation - LHD INSTALLATION 1. Install clutch master cylinder (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Removal - LHD > Page 4489 2. Insert tube into master cylinder port and install retaining clip (5). 3. Connect clutch master cylinder supply hose (2) to brake master cylinder reservoir (1). 4. Verify that brake master cylinder reservoir is full and cap is off. 5. Install clutch master cylinder body to clutch pedal and 1/4 turn to secure. 6. Connect clutch master cylinder rod to clutch pedal pin. An audible "click" should be heard. 7. Install lower instrument panel bezel. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Removal - LHD > Page 4490 8. Connect battery negative cable. 9. Install air cleaner assembly (1). 10. Verify that brake master cylinder reservoir is full. Top off with DOT 3 brake fluid if necessary. 11. Bleed clutch system. 12. Actuate clutch pedal a minimum of fifteen times to allow any air ingested into the system to vent to the master cylinder reservoir. If residual air becomes trapped in the system, it is necessary to bleed the clutch hydraulic system. 13. Verify proper clutch release system operation. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Description and Operation Clutch Slave Cylinder: Description and Operation DESCRIPTION The clutch slave cylinder (1) consists of a hydraulic piston and cylinder, seal and return spring. It is fastened to the transaxle bellhousing. The slave cylinder is connected to the clutch master cylinder hydraulic pipe, which is retained to the cylinder by a pair of retainer clips, and has a bleed port to facilitate the removal of air from the system. The clutch release system (1) utilizes a slave cylinder of a concentric design, having all components fixed about the same axis. The concentric slave cylinder (CSC) is mounted to the inside of the clutch bellhousing and is serviced only as an assembly. The concentric design permits high efficiency, resulting in low and consistent pedal effort, as well as automatic adjustment to compensate for clutch disc wear. The CSC is a self-contained unit, consisting of a main body (2) and piston (6), spring (5), integrated release bearing (1), and a rubber boot (4). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair > Removal Clutch Slave Cylinder: Service and Repair Removal REMOVAL NOTE: To prevent drainage of clutch master cylinder assembly upon slave cylinder removal, it is necessary to make sure brake master cylinder fluid level is full and reservoir cap is installed tight. 1. Remove transaxle from vehicle. 2. Remove bolts to slave cylinder-to-clutch bellhousing bolts and remove slave cylinder (1) from transaxle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair > Removal > Page 4496 Clutch Slave Cylinder: Service and Repair Installation INSTALLATION 1. Install slave cylinder (1) to transaxle using new bolts. NOTE: Torque three CSC body screws first, then torque the fluid tube attachment. 2. Torque slave cylinder-to-case bolts in three steps: - 2 Nm (18 in. lbs.) - 5 Nm (44 in. lbs.) - 8.4 Nm (74 in. lbs.) 3. Install transaxle. 4. Bleed clutch hydraulic system. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Technical Service Bulletins > Customer Interest: > 06-006-07 > Dec > 07 > M/T - Clutch Pedal Squeaks When Operated Clutch Pedal Assembly: Customer Interest M/T - Clutch Pedal Squeaks When Operated NUMBER: 06-006-07 GROUP: Clutch DATE: December 5, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 06-001-06, DATED OCTOBER 17, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF CLEAN POINTS. SUBJECT: Clutch Pedal Squeak OVERVIEW: This bulletin involves lubricating the clutch master cylinder pushrod ball socket (attachment at clutch pedal arm). MODELS: 2007 (JS) Sebring 2007 (PM) Caliber 2007 (MK49) Compass NOTE: **This information applies to models equipped with a T-355 or BG6 Manual Transmission (Sales Code DD7 or DEF) built prior to February 8, 2007 (MDH0208XX)**. SYMPTOM/CONDITION: A squeak sound may be heard when applying or releasing the clutch pedal. This may be more noticeable in cold temperatures. DIAGNOSIS: If the customer describes a squeak sound when applying the clutch pedal, perform the Repair Procedure PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove the lower instrument panel bezel. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Technical Service Bulletins > Customer Interest: > 06-006-07 > Dec > 07 > M/T - Clutch Pedal Squeaks When Operated > Page 4505 2. Disconnect clutch master cylinder pushrod from clutch pedal arm (Fig. 1). 3. Lubricate the pushrod ball socket with a small amount of Silicone Grease pn 05019061AA. 4. Connect clutch master cylinder rod to clutch pedal pin. An audible "click" should be heard. 5. Install lower instrument panel bezel. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Technical Service Bulletins > Customer Interest: > 06-006-07 > Dec > 07 > M/T - Clutch Pedal Squeaks When Operated > Page 4506 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Technical Service Bulletins > Customer Interest: > 06-005-07 > Oct > 07 > M/T - Squeak When Operating Clutch Pedal Clutch Pedal Assembly: Customer Interest M/T - Squeak When Operating Clutch Pedal NUMBER: 06-005-07 GROUP: Clutch DATE: October 31, 2007 SUBJECT: Clutch Pedal Squeak OVERVIEW: This bulletin involves lubricating the clutch return spring. MODELS: 2007 - 2008 (JS41) Avenger / Sebring 2007 - 2008 (PM) Caliber 2007 - 2008 (MK49) Compass 2007 - 2008 (MK74) Patriot NOTE: This information applies to models equipped with a T-355 or BG6 Manual Transmission (Sales Code DD7 or DEF) built prior to August 6, 2007 (MDH0806XX). SYMPTOM/CONDITION: A squeak sound may be heard when applying or releasing the clutch pedal. DIAGNOSIS: If the customer describes a squeak sound when applying the clutch pedal, perform the Repair Procedure PARTS REQUIRED: REPAIR PROCEDURE: 1. Using grease pn 04318066AB, lubricate the clutch return spring 2. Verify the squeak is eliminated. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Technical Service Bulletins > Customer Interest: > 06-005-07 > Oct > 07 > M/T - Squeak When Operating Clutch Pedal > Page 4511 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Pedal Assembly: > 06-006-07 > Dec > 07 > M/T Clutch Pedal Squeaks When Operated Clutch Pedal Assembly: All Technical Service Bulletins M/T - Clutch Pedal Squeaks When Operated NUMBER: 06-006-07 GROUP: Clutch DATE: December 5, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 06-001-06, DATED OCTOBER 17, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF CLEAN POINTS. SUBJECT: Clutch Pedal Squeak OVERVIEW: This bulletin involves lubricating the clutch master cylinder pushrod ball socket (attachment at clutch pedal arm). MODELS: 2007 (JS) Sebring 2007 (PM) Caliber 2007 (MK49) Compass NOTE: **This information applies to models equipped with a T-355 or BG6 Manual Transmission (Sales Code DD7 or DEF) built prior to February 8, 2007 (MDH0208XX)**. SYMPTOM/CONDITION: A squeak sound may be heard when applying or releasing the clutch pedal. This may be more noticeable in cold temperatures. DIAGNOSIS: If the customer describes a squeak sound when applying the clutch pedal, perform the Repair Procedure PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove the lower instrument panel bezel. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Pedal Assembly: > 06-006-07 > Dec > 07 > M/T Clutch Pedal Squeaks When Operated > Page 4517 2. Disconnect clutch master cylinder pushrod from clutch pedal arm (Fig. 1). 3. Lubricate the pushrod ball socket with a small amount of Silicone Grease pn 05019061AA. 4. Connect clutch master cylinder rod to clutch pedal pin. An audible "click" should be heard. 5. Install lower instrument panel bezel. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Pedal Assembly: > 06-006-07 > Dec > 07 > M/T Clutch Pedal Squeaks When Operated > Page 4518 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Pedal Assembly: > 06-005-07 > Oct > 07 > M/T Squeak When Operating Clutch Pedal Clutch Pedal Assembly: All Technical Service Bulletins M/T - Squeak When Operating Clutch Pedal NUMBER: 06-005-07 GROUP: Clutch DATE: October 31, 2007 SUBJECT: Clutch Pedal Squeak OVERVIEW: This bulletin involves lubricating the clutch return spring. MODELS: 2007 - 2008 (JS41) Avenger / Sebring 2007 - 2008 (PM) Caliber 2007 - 2008 (MK49) Compass 2007 - 2008 (MK74) Patriot NOTE: This information applies to models equipped with a T-355 or BG6 Manual Transmission (Sales Code DD7 or DEF) built prior to August 6, 2007 (MDH0806XX). SYMPTOM/CONDITION: A squeak sound may be heard when applying or releasing the clutch pedal. DIAGNOSIS: If the customer describes a squeak sound when applying the clutch pedal, perform the Repair Procedure PARTS REQUIRED: REPAIR PROCEDURE: 1. Using grease pn 04318066AB, lubricate the clutch return spring 2. Verify the squeak is eliminated. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Pedal Assembly: > 06-005-07 > Oct > 07 > M/T Squeak When Operating Clutch Pedal > Page 4523 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Pedal Assembly: > 06-002-06 > Dec > 06 > Clutch - Clutch Pedal Push Back Clutch Pedal Assembly: All Technical Service Bulletins Clutch - Clutch Pedal Push Back NUMBER: 06-002-06 GROUP: Clutch DATE: December 8, 2006 SUBJECT: Clutch Pedal Push Back OVERVIEW: This bulletin involves removing the over-center spring (attachment at clutch pedal arm). MODELS: 2007 (JS) Sebring 2007 (PM) Caliber 2007 (MK49) Compass NOTE: This information applies to models vehicles equipped with a 2.0L Diesel engine (sales code ECD) and a Manual Transmission (Sales Code DEF) built before January 1, 2007 (MDH 0101XX). SYMPTOM/CONDITION: A clutch pedal push back may be felt toward the end (engaged) of the clutch pedal travel. This may be described as a little bump felt just before the end of the pedal stroke. DIAGNOSIS: If the customer describes the symptom condition, perform the Repair Procedure REPAIR PROCEDURE: 1. Remove the lower instrument panel bezel. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Pedal Assembly: > 06-002-06 > Dec > 06 > Clutch - Clutch Pedal Push Back > Page 4528 2. Disconnect clutch master cylinder pushrod from clutch pedal arm (Fig. 1). 3. Remove the rubber downstop bumper (Fig. 1). 4. Push the clutch pedal all the way down. NOTE: Be sure the rubber downstop bumper is removed. This will allow for more pedal travel to assist in the next step. 5. Pull the overcenter spring and bracket bushing out of the pedal arm bracket. 6. Pry overcenter clutch springs out of both side bushings and discard. 7. Remove both side bushings and discard. 8. Release clutch pedal. 9. Reinstall the rubber downstop bumper. 10. Reconnect the clutch master cylinder pushrod to the clutch pedal arm (Fig. 1). 11. Install the lower instrument panel bezel. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Pedal Assembly: > 06-002-06 > Dec > 06 > Clutch - Clutch Pedal Push Back > Page 4529 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Pedal Assembly: > 06-002-06 > Dec > 06 > Clutch Clutch Pedal Push Back Clutch Pedal Assembly: All Technical Service Bulletins Clutch - Clutch Pedal Push Back NUMBER: 06-002-06 GROUP: Clutch DATE: December 8, 2006 SUBJECT: Clutch Pedal Push Back OVERVIEW: This bulletin involves removing the over-center spring (attachment at clutch pedal arm). MODELS: 2007 (JS) Sebring 2007 (PM) Caliber 2007 (MK49) Compass NOTE: This information applies to models vehicles equipped with a 2.0L Diesel engine (sales code ECD) and a Manual Transmission (Sales Code DEF) built before January 1, 2007 (MDH 0101XX). SYMPTOM/CONDITION: A clutch pedal push back may be felt toward the end (engaged) of the clutch pedal travel. This may be described as a little bump felt just before the end of the pedal stroke. DIAGNOSIS: If the customer describes the symptom condition, perform the Repair Procedure REPAIR PROCEDURE: 1. Remove the lower instrument panel bezel. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Pedal Assembly: > 06-002-06 > Dec > 06 > Clutch Clutch Pedal Push Back > Page 4535 2. Disconnect clutch master cylinder pushrod from clutch pedal arm (Fig. 1). 3. Remove the rubber downstop bumper (Fig. 1). 4. Push the clutch pedal all the way down. NOTE: Be sure the rubber downstop bumper is removed. This will allow for more pedal travel to assist in the next step. 5. Pull the overcenter spring and bracket bushing out of the pedal arm bracket. 6. Pry overcenter clutch springs out of both side bushings and discard. 7. Remove both side bushings and discard. 8. Release clutch pedal. 9. Reinstall the rubber downstop bumper. 10. Reconnect the clutch master cylinder pushrod to the clutch pedal arm (Fig. 1). 11. Install the lower instrument panel bezel. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Pedal Assembly: > 06-002-06 > Dec > 06 > Clutch Clutch Pedal Push Back > Page 4536 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications Pressure Plate: Specifications Pressure Plate to Flywheel bolts Tighten to ........................................................................................ .......................................................................................................... 28 Nm (23 ft.lbs.) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Description and Operation > Description Pressure Plate: Description and Operation Description DESCRIPTION The modular clutch assembly (1) is located between the engine and manual transaxle in the transaxle bellhousing, and is responsible for transmitting engine power to the transaxle. The modular clutch is an assembly which incorporates a self-adjusting design and consists of the following components: - Flywheel - Clutch Disc - Pressure Plate - Diaphragm Spring - Adjusting Ring - Sensor - Cover Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Description and Operation > Description > Page 4542 Pressure Plate: Description and Operation Operation OPERATION The modular clutch assembly is designed to transmit power from the engine to the manual transaxle. This is accomplished by the friction and clamping force generated when the spring loaded pressure plate locks the clutch disc to the flywheel. The clutch disc, which is splined to the transaxle input shaft, transmits power until the center of the diaphragm spring is depressed, and the clamp force is removed from the disc. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Description and Operation > Description > Page 4543 The self-adjusting feature of this clutch assembly relies on the sensor ring (4) and the adjuster ring (5), which works its way around a ramped clutch cover (2), taking up clearance as the clutch disc wears and maintaining diaphragm spring force throughout the life of the clutch. The primary benefits of this design are reduced pedal effort, constant release load over clutch life, and extended clutch life. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Service and Repair > Clutch Disc and Pressure Plate Pressure Plate: Service and Repair Clutch Disc and Pressure Plate Removal REMOVAL DIESEL 1. Remove transaxle assembly. 2. Mark position of pressure plate (3) on flywheel (1) with paint or scribe for assembly reference. 3. Loosen and remove six pressure plate-to-flywheel bolts. Remove pressure plate (3) and clutch disc (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Service and Repair > Clutch Disc and Pressure Plate > Page 4546 4. Remove eight flywheel-to-crankshaft bolts and remove flywheel assembly (1). GAS 1. Remove transaxle assembly. 2. Remove the modular clutch assembly (1). Installation INSTALLATION DIESEL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Service and Repair > Clutch Disc and Pressure Plate > Page 4547 1. Inspect clutch release bearing and lever for excessive wear and replace as necessary. The release bearing is integral to the Concentric Slave Cylinder (CSC). 2. Clean the surfaces of the flywheel (1) and pressure plate to make certain that all oil, grease, and rust have been removed. 3. Verify the crankshaft mounting flange is free of debris, oil, grease, etc. Position the flywheel (1) onto the engine crankshaft. 4. Install flywheel to crankshaft. Install eight (8) flywheel-to-crankshaft bolts and tighten to 45 Nm (33 ft. lbs.) plus an additional 1/4 turn (90 degrees). 5. Apply a very light coating of grease to the splines in the clutch disc hub. 6. Position the clutch disc (2) to the flywheel (1). Make sure the side marked "FLYWHEEL SIDE" faces the flywheel (1). 7. Install the clutch pressure plate (1) to the flywheel and clutch disc. Finger tighten the six pressure plate-to-flywheel bolts. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Service and Repair > Clutch Disc and Pressure Plate > Page 4548 8. Use Clutch Alignment Tool 6724 (3) to position the clutch disc (2) to the center of the flywheel (1). 9. Tighten pressure plate bolts (2) evenly and in rotation a few threads at a time The bolts must be tightened evenly and to specified torque to avoid distorting the pressure plate. 10. Using a "criss-cross" pattern, torque pressure plate bolts (2) to 31 Nm (23 ft. lbs.). Remove the clutch disc alignment tool. 11. Apply light coat of MOPAR(R) High Temperature Bearing Grease or equivalent to clutch disc hub and splines of transmission input shaft. CAUTION: Do not over lubricate shaft splines. This will result in grease contamination of disc. 12. Install transaxle. GAS Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Service and Repair > Clutch Disc and Pressure Plate > Page 4549 1. Install new modular clutch assembly onto input shaft of transmission. 2. Install the transmission. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Service and Repair > Clutch Disc and Pressure Plate > Page 4550 Pressure Plate: Service and Repair Modular Clutch Removal REMOVAL 1. Remove transaxle (3) from vehicle. 2. Remove modular clutch assembly (1) from transaxle input shaft. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Service and Repair > Clutch Disc and Pressure Plate > Page 4551 3. Disassemble modular clutch assembly (If individual parts are available). Remove six pressure plate-to-flywheel bolts (1). Remove pressure plate (2) and disc from flywheel. Inspection INSPECTION Fluid contamination is a frequent cause of clutch malfunctions. Oil, grease, water, or other fluids on the clutch contact surfaces will cause faulty operation. During inspection, note if any components are contaminated. Look for evidence of oil, grease, or water/road splash on clutch components. OIL CONTAMINATION Oil contamination indicates a leak at the rear main seal and/or transaxle input shaft. Oil leaks produce a residue of oil on the transaxle housing interior, clutch cover and flywheel. Heat buildup caused by slippage can bake the oil residue onto the components. This glaze-like residue ranges in color from amber to black. GREASE CONTAMINATION Grease contamination is usually a product of over-lubrication. During clutch service, apply only a small amount of grease to the input shaft splines. Excess grease may be thrown off during operation, contaminating the disc. ROAD SPLASH/WATER CONTAMINATION Road splash contamination is usually caused by driving the vehicle through deep water puddles. Water can be forced into the clutch housing, causing clutch components to become contaminated. Facing of disc will absorb moisture and bond to the flywheel and/or, pressure plate, if vehicle is allowed to stand for some time before use. If this condition occurs, replacement of clutch assembly may be required. Drive the vehicle until normal clutch operating temperature has been obtained. This will dry off disc assembly, pressure plate, and flywheel. Installation INSTALLATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Service and Repair > Clutch Disc and Pressure Plate > Page 4552 1. Install clutch module onto input shaft. 2. Install transaxle into vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 Control Module: Customer Interest A/T - MIL ON Possible DTC P2004 NUMBER: 18-032-07 GROUP: Vehicle Performance DATE: May 16, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 7.04 SPI OR HIGHER FOR THIS BULLETIN. SUBJECT: Flash: MIL Illumination with DIG P2004 OVERVIEW: This bulletin involves selectively erasing and reprogramming the GPEC Powertrain Control Module (PCM) with new software and replacing the intake manifold as required. CAUTION: VEHICLES EQUIPPED WITH A CVT TRANSMISSION MUST HAVE THE TRANSMISSION CONTROL MODULE (TCM) CHECKED FOR THE LATEST SOFTWARE LEVEL WHENEVER THE PCM SOFTWARE IS UPGRADED. IF NEWER TCM SOFTWARE IS AVAILABLE, IT MUST BE INSTALLED. MODELS: 2007-2008 (JS) Avenger 2007 (JS) Sebring 2008 (J527) Sebring Convertible 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to models equipped with a 1.8L, 2.0L or 2.4L gasoline engine (Sales Code EBA, ECN or ED3) as follows: Flash portion applies to PM/MK models built through April 21, 2007 (MDH 0421 XX) and JS models built through May 15, 2007 (0515XX). The Intake Manifold Replacement portion applies to models built through March 22, 2007 (MDHO322XX). SYMPTOM/CONDITION: Some customers may experience MIL Illumination with no other symptoms. The condition may occur intermittently. Further investigation by the technician may find DTC P2004 - Intake Manifold Runner Control Stuck Open as the cause for MIL Illumination. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine Systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Perform the standard diagnostic procedures for DIG P2004. If the diagnostics do not lead to the failure, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 4562 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and/or 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 7.04 SPI software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service> StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options d. Select "ECU Flash e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 4563 j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. m. Turn the ignition switch to the OFF position for no less than 15 seconds. n. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING 5n OR 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. PM/MK Models equipped with a CVT must have the TCM reprogrammed as follows: 6. Using the StarSCAN(R) at the "Home screen": a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. 7. Is the TCM part number recorded in step 6e above, the same as the new pin shown on the "Flash File List" screen? a. Yes > No further action is necessary. Proceed to Step 9. b. No > the TCM will require flash reprogramming, proceed to Step 8. 8. Flash reprogram the TCM as follows: a. From the "Flash File List screen, select "Download to Scantool". b. Select "Close" after the download is complete, then select "Back". c. Highlight the listed calibration. d. Select "Update Controller". Follow on screen instructions. e. When the update is complete, select "OK". f. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. g. Turn the ignition switch to the OFF position for no less than 15 seconds. h. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP Sn and 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the TCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list.** Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 4564 NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig.1). 1. Vehicles built through March 22, 2007 will require a new Intake Manifold pn 04884495AF. Following the procedures listed in DealerCONNECT > TechCONNECT replace the intake manifold. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B Technical Service Bulletin # 18-019-06 Date: 060607 A/T Controls - MIL ON/DTC's P0602/P167A or P161B NUMBER: 18-019-06 GROUP: Vehicle Performance DATE: June 7, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: Flash: MIL Illumination - DTC's P0602, P167A, or P161B OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (TCM) with new software and the Powertrain Control Module (PCM) with new software. WARNING: BOTH CONTROLLERS (TCM AND PCM) MUST BE REPROGRAMMED. THIS UPDATE MUST BE COMPLETED AS A COORDINATED CHANGE. IF THE PCM IS NOT UPDATED, MIL ILLUMINATION CAN OCCUR AND DTC U1424 (IMPLAUSIBLE ENGINE TORQUE MESSAGE RECEIVED) WILL BE RECORDED IN THE TCM. MODELS: 2007 (PM) Caliber NOTE: This bulletin applies to vehicles equipped with a Continuously Variable Transmission (CVT), (sales code DAV), built on or before June 1, 2006 (MDH 0601XX). SYMPTOM/CONDITION: The customer may experience Malfunction Indicator Lamp (MIL) illumination. The technician may find the following Diagnostic Trouble Codes (DTC's) in the TCM: ^ P0602-Control Module Programming Error/Not Programmed ^ P167A-Calibration Mismatch ^ P161B-Battery Disconnect / TCM Internal DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes MIL Illumination and the technician finds any of the DTC's listed above, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B > Page 4569 SPECIAL TOOLS / EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. TCM - Repair Procedure - Using the Internet to Retrieve the Flash File NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 6.06 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old TCM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B > Page 4570 b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". I. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. NOTE: Due to the TCM/PCM programming procedure, a DTC may be set in other modules (BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTC's". Press "Clear All Stored DTC's" if there are any DTC's shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 6. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). PCM Repair Procedure - Using the Internet to Retrieve the Flash File CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 6.06 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B > Page 4571 StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the PCM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. m. Turn the ignition switch to the OFF position for no less than 15 seconds. n. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 6. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 Control Module: All Technical Service Bulletins A/T - MIL ON Possible DTC P2004 NUMBER: 18-032-07 GROUP: Vehicle Performance DATE: May 16, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 7.04 SPI OR HIGHER FOR THIS BULLETIN. SUBJECT: Flash: MIL Illumination with DIG P2004 OVERVIEW: This bulletin involves selectively erasing and reprogramming the GPEC Powertrain Control Module (PCM) with new software and replacing the intake manifold as required. CAUTION: VEHICLES EQUIPPED WITH A CVT TRANSMISSION MUST HAVE THE TRANSMISSION CONTROL MODULE (TCM) CHECKED FOR THE LATEST SOFTWARE LEVEL WHENEVER THE PCM SOFTWARE IS UPGRADED. IF NEWER TCM SOFTWARE IS AVAILABLE, IT MUST BE INSTALLED. MODELS: 2007-2008 (JS) Avenger 2007 (JS) Sebring 2008 (J527) Sebring Convertible 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to models equipped with a 1.8L, 2.0L or 2.4L gasoline engine (Sales Code EBA, ECN or ED3) as follows: Flash portion applies to PM/MK models built through April 21, 2007 (MDH 0421 XX) and JS models built through May 15, 2007 (0515XX). The Intake Manifold Replacement portion applies to models built through March 22, 2007 (MDHO322XX). SYMPTOM/CONDITION: Some customers may experience MIL Illumination with no other symptoms. The condition may occur intermittently. Further investigation by the technician may find DTC P2004 - Intake Manifold Runner Control Stuck Open as the cause for MIL Illumination. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine Systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Perform the standard diagnostic procedures for DIG P2004. If the diagnostics do not lead to the failure, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 4577 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and/or 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 7.04 SPI software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service> StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options d. Select "ECU Flash e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 4578 j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. m. Turn the ignition switch to the OFF position for no less than 15 seconds. n. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING 5n OR 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. PM/MK Models equipped with a CVT must have the TCM reprogrammed as follows: 6. Using the StarSCAN(R) at the "Home screen": a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. 7. Is the TCM part number recorded in step 6e above, the same as the new pin shown on the "Flash File List" screen? a. Yes > No further action is necessary. Proceed to Step 9. b. No > the TCM will require flash reprogramming, proceed to Step 8. 8. Flash reprogram the TCM as follows: a. From the "Flash File List screen, select "Download to Scantool". b. Select "Close" after the download is complete, then select "Back". c. Highlight the listed calibration. d. Select "Update Controller". Follow on screen instructions. e. When the update is complete, select "OK". f. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. g. Turn the ignition switch to the OFF position for no less than 15 seconds. h. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP Sn and 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the TCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list.** Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 4579 NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig.1). 1. Vehicles built through March 22, 2007 will require a new Intake Manifold pn 04884495AF. Following the procedures listed in DealerCONNECT > TechCONNECT replace the intake manifold. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B Technical Service Bulletin # 18-019-06 Date: 060607 A/T Controls - MIL ON/DTC's P0602/P167A or P161B NUMBER: 18-019-06 GROUP: Vehicle Performance DATE: June 7, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: Flash: MIL Illumination - DTC's P0602, P167A, or P161B OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (TCM) with new software and the Powertrain Control Module (PCM) with new software. WARNING: BOTH CONTROLLERS (TCM AND PCM) MUST BE REPROGRAMMED. THIS UPDATE MUST BE COMPLETED AS A COORDINATED CHANGE. IF THE PCM IS NOT UPDATED, MIL ILLUMINATION CAN OCCUR AND DTC U1424 (IMPLAUSIBLE ENGINE TORQUE MESSAGE RECEIVED) WILL BE RECORDED IN THE TCM. MODELS: 2007 (PM) Caliber NOTE: This bulletin applies to vehicles equipped with a Continuously Variable Transmission (CVT), (sales code DAV), built on or before June 1, 2006 (MDH 0601XX). SYMPTOM/CONDITION: The customer may experience Malfunction Indicator Lamp (MIL) illumination. The technician may find the following Diagnostic Trouble Codes (DTC's) in the TCM: ^ P0602-Control Module Programming Error/Not Programmed ^ P167A-Calibration Mismatch ^ P161B-Battery Disconnect / TCM Internal DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes MIL Illumination and the technician finds any of the DTC's listed above, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B > Page 4584 SPECIAL TOOLS / EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. TCM - Repair Procedure - Using the Internet to Retrieve the Flash File NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 6.06 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old TCM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B > Page 4585 b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". I. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. NOTE: Due to the TCM/PCM programming procedure, a DTC may be set in other modules (BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTC's". Press "Clear All Stored DTC's" if there are any DTC's shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 6. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). PCM Repair Procedure - Using the Internet to Retrieve the Flash File CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 6.06 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B > Page 4586 StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the PCM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. m. Turn the ignition switch to the OFF position for no less than 15 seconds. n. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 6. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Differential, CVT > Differential Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - CVT: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Differential, CVT > Differential Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4592 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - CVT: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4597 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 Control Module: Customer Interest A/T - MIL ON Possible DTC P2004 NUMBER: 18-032-07 GROUP: Vehicle Performance DATE: May 16, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 7.04 SPI OR HIGHER FOR THIS BULLETIN. SUBJECT: Flash: MIL Illumination with DIG P2004 OVERVIEW: This bulletin involves selectively erasing and reprogramming the GPEC Powertrain Control Module (PCM) with new software and replacing the intake manifold as required. CAUTION: VEHICLES EQUIPPED WITH A CVT TRANSMISSION MUST HAVE THE TRANSMISSION CONTROL MODULE (TCM) CHECKED FOR THE LATEST SOFTWARE LEVEL WHENEVER THE PCM SOFTWARE IS UPGRADED. IF NEWER TCM SOFTWARE IS AVAILABLE, IT MUST BE INSTALLED. MODELS: 2007-2008 (JS) Avenger 2007 (JS) Sebring 2008 (J527) Sebring Convertible 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to models equipped with a 1.8L, 2.0L or 2.4L gasoline engine (Sales Code EBA, ECN or ED3) as follows: Flash portion applies to PM/MK models built through April 21, 2007 (MDH 0421 XX) and JS models built through May 15, 2007 (0515XX). The Intake Manifold Replacement portion applies to models built through March 22, 2007 (MDHO322XX). SYMPTOM/CONDITION: Some customers may experience MIL Illumination with no other symptoms. The condition may occur intermittently. Further investigation by the technician may find DTC P2004 - Intake Manifold Runner Control Stuck Open as the cause for MIL Illumination. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine Systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Perform the standard diagnostic procedures for DIG P2004. If the diagnostics do not lead to the failure, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 4607 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and/or 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 7.04 SPI software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service> StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options d. Select "ECU Flash e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 4608 j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. m. Turn the ignition switch to the OFF position for no less than 15 seconds. n. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING 5n OR 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. PM/MK Models equipped with a CVT must have the TCM reprogrammed as follows: 6. Using the StarSCAN(R) at the "Home screen": a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. 7. Is the TCM part number recorded in step 6e above, the same as the new pin shown on the "Flash File List" screen? a. Yes > No further action is necessary. Proceed to Step 9. b. No > the TCM will require flash reprogramming, proceed to Step 8. 8. Flash reprogram the TCM as follows: a. From the "Flash File List screen, select "Download to Scantool". b. Select "Close" after the download is complete, then select "Back". c. Highlight the listed calibration. d. Select "Update Controller". Follow on screen instructions. e. When the update is complete, select "OK". f. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. g. Turn the ignition switch to the OFF position for no less than 15 seconds. h. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP Sn and 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the TCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list.** Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 4609 NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig.1). 1. Vehicles built through March 22, 2007 will require a new Intake Manifold pn 04884495AF. Following the procedures listed in DealerCONNECT > TechCONNECT replace the intake manifold. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B Technical Service Bulletin # 18-019-06 Date: 060607 A/T Controls - MIL ON/DTC's P0602/P167A or P161B NUMBER: 18-019-06 GROUP: Vehicle Performance DATE: June 7, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: Flash: MIL Illumination - DTC's P0602, P167A, or P161B OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (TCM) with new software and the Powertrain Control Module (PCM) with new software. WARNING: BOTH CONTROLLERS (TCM AND PCM) MUST BE REPROGRAMMED. THIS UPDATE MUST BE COMPLETED AS A COORDINATED CHANGE. IF THE PCM IS NOT UPDATED, MIL ILLUMINATION CAN OCCUR AND DTC U1424 (IMPLAUSIBLE ENGINE TORQUE MESSAGE RECEIVED) WILL BE RECORDED IN THE TCM. MODELS: 2007 (PM) Caliber NOTE: This bulletin applies to vehicles equipped with a Continuously Variable Transmission (CVT), (sales code DAV), built on or before June 1, 2006 (MDH 0601XX). SYMPTOM/CONDITION: The customer may experience Malfunction Indicator Lamp (MIL) illumination. The technician may find the following Diagnostic Trouble Codes (DTC's) in the TCM: ^ P0602-Control Module Programming Error/Not Programmed ^ P167A-Calibration Mismatch ^ P161B-Battery Disconnect / TCM Internal DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes MIL Illumination and the technician finds any of the DTC's listed above, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B > Page 4614 SPECIAL TOOLS / EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. TCM - Repair Procedure - Using the Internet to Retrieve the Flash File NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 6.06 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old TCM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B > Page 4615 b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". I. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. NOTE: Due to the TCM/PCM programming procedure, a DTC may be set in other modules (BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTC's". Press "Clear All Stored DTC's" if there are any DTC's shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 6. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). PCM Repair Procedure - Using the Internet to Retrieve the Flash File CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 6.06 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B > Page 4616 StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the PCM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. m. Turn the ignition switch to the OFF position for no less than 15 seconds. n. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 6. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 Control Module: All Technical Service Bulletins A/T - MIL ON Possible DTC P2004 NUMBER: 18-032-07 GROUP: Vehicle Performance DATE: May 16, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 7.04 SPI OR HIGHER FOR THIS BULLETIN. SUBJECT: Flash: MIL Illumination with DIG P2004 OVERVIEW: This bulletin involves selectively erasing and reprogramming the GPEC Powertrain Control Module (PCM) with new software and replacing the intake manifold as required. CAUTION: VEHICLES EQUIPPED WITH A CVT TRANSMISSION MUST HAVE THE TRANSMISSION CONTROL MODULE (TCM) CHECKED FOR THE LATEST SOFTWARE LEVEL WHENEVER THE PCM SOFTWARE IS UPGRADED. IF NEWER TCM SOFTWARE IS AVAILABLE, IT MUST BE INSTALLED. MODELS: 2007-2008 (JS) Avenger 2007 (JS) Sebring 2008 (J527) Sebring Convertible 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to models equipped with a 1.8L, 2.0L or 2.4L gasoline engine (Sales Code EBA, ECN or ED3) as follows: Flash portion applies to PM/MK models built through April 21, 2007 (MDH 0421 XX) and JS models built through May 15, 2007 (0515XX). The Intake Manifold Replacement portion applies to models built through March 22, 2007 (MDHO322XX). SYMPTOM/CONDITION: Some customers may experience MIL Illumination with no other symptoms. The condition may occur intermittently. Further investigation by the technician may find DTC P2004 - Intake Manifold Runner Control Stuck Open as the cause for MIL Illumination. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine Systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Perform the standard diagnostic procedures for DIG P2004. If the diagnostics do not lead to the failure, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 4622 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and/or 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 7.04 SPI software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service> StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options d. Select "ECU Flash e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 4623 j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. m. Turn the ignition switch to the OFF position for no less than 15 seconds. n. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING 5n OR 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. PM/MK Models equipped with a CVT must have the TCM reprogrammed as follows: 6. Using the StarSCAN(R) at the "Home screen": a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. 7. Is the TCM part number recorded in step 6e above, the same as the new pin shown on the "Flash File List" screen? a. Yes > No further action is necessary. Proceed to Step 9. b. No > the TCM will require flash reprogramming, proceed to Step 8. 8. Flash reprogram the TCM as follows: a. From the "Flash File List screen, select "Download to Scantool". b. Select "Close" after the download is complete, then select "Back". c. Highlight the listed calibration. d. Select "Update Controller". Follow on screen instructions. e. When the update is complete, select "OK". f. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. g. Turn the ignition switch to the OFF position for no less than 15 seconds. h. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP Sn and 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the TCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list.** Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 4624 NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig.1). 1. Vehicles built through March 22, 2007 will require a new Intake Manifold pn 04884495AF. Following the procedures listed in DealerCONNECT > TechCONNECT replace the intake manifold. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B Technical Service Bulletin # 18-019-06 Date: 060607 A/T Controls - MIL ON/DTC's P0602/P167A or P161B NUMBER: 18-019-06 GROUP: Vehicle Performance DATE: June 7, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: Flash: MIL Illumination - DTC's P0602, P167A, or P161B OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (TCM) with new software and the Powertrain Control Module (PCM) with new software. WARNING: BOTH CONTROLLERS (TCM AND PCM) MUST BE REPROGRAMMED. THIS UPDATE MUST BE COMPLETED AS A COORDINATED CHANGE. IF THE PCM IS NOT UPDATED, MIL ILLUMINATION CAN OCCUR AND DTC U1424 (IMPLAUSIBLE ENGINE TORQUE MESSAGE RECEIVED) WILL BE RECORDED IN THE TCM. MODELS: 2007 (PM) Caliber NOTE: This bulletin applies to vehicles equipped with a Continuously Variable Transmission (CVT), (sales code DAV), built on or before June 1, 2006 (MDH 0601XX). SYMPTOM/CONDITION: The customer may experience Malfunction Indicator Lamp (MIL) illumination. The technician may find the following Diagnostic Trouble Codes (DTC's) in the TCM: ^ P0602-Control Module Programming Error/Not Programmed ^ P167A-Calibration Mismatch ^ P161B-Battery Disconnect / TCM Internal DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes MIL Illumination and the technician finds any of the DTC's listed above, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B > Page 4629 SPECIAL TOOLS / EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. TCM - Repair Procedure - Using the Internet to Retrieve the Flash File NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 6.06 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old TCM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B > Page 4630 b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". I. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. NOTE: Due to the TCM/PCM programming procedure, a DTC may be set in other modules (BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTC's". Press "Clear All Stored DTC's" if there are any DTC's shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 6. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). PCM Repair Procedure - Using the Internet to Retrieve the Flash File CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 6.06 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B > Page 4631 StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the PCM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. m. Turn the ignition switch to the OFF position for no less than 15 seconds. n. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 6. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shifter CVT > Component Information > Technical Service Bulletins > A/T - CVT Shifter Diagnostics Shifter CVT: Technical Service Bulletins A/T - CVT Shifter Diagnostics NUMBER: 21-013-06 REV. A GROUP: Transmission DATE: October 5, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-013-06, DATED MAY 5, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES AN ADDITIONAL MODEL WITH A DESCRIPTION ON LABOR TIMES THAT SHOULD BE USED WHEN REPAIRS ARE MADE. SUBJECT: Continuously Variable Transmission (CVI) Automatic Shifter Diagnostics MODELS: 2007 (PM) Caliber **2007 (MK-49174) Compass/Patriot** **2007 (JS) Sebring Sedan/Stratus Sedan** NOTE: This bulletin applies to vehicles equipped with an Continuously Variable Transmission (CVT) (sales code DAV). DISCUSSION: The Automatic Transmission Shifter for 2007 PM, MK and JS vehicles equipped with a CVI transmission includes several new features: i. The Shifter's serpentine pattern does not require the shifter to have a button on the knob to release it from "Park". There is a blocking lever within the Shifter that prevents undesired shifting out of "Park". ii. The shifter has a solenoid which is actuated by depressing the brake pedal. This prevents shifting out of "Park" without the brake pedal being depressed. To operate the solenoid, the ignition must be in the "On" or "Run" position and the brake pedal must be depressed. The Brake Switch sends a signal to the Cabin Compartment Node (CCN) and the CCN, in turn, energizes the solenoid that moves the Park Lock Lever to allow the driver to shift out of "Park". On the right side of the Console Pod is a plug that allows access to the Park Lock Lever for manual operation. iii. The Interlock Cable is attached to a lever within the Shifter that prevents the Shift Lever from moving out of "Park" without the key (theft prevention). The Interlock Cable adjustment is preset at the factory. When properly adjusted, the Interlock System prevents the key being removed from the Key Cylinder when the Shift Lever is in a position other then "Park". Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shifter CVT > Component Information > Technical Service Bulletins > A/T - CVT Shifter Diagnostics > Page 4636 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shifter CVT > Component Information > Technical Service Bulletins > A/T - CVT Shifter Diagnostics > Page 4637 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shifter CVT > Component Information > Technical Service Bulletins > A/T - CVT Shifter Diagnostics > Page 4638 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shifter CVT > Component Information > Technical Service Bulletins > A/T - CVT Shifter Diagnostics > Page 4639 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shifter CVT > Component Information > Technical Service Bulletins > A/T - CVT Shifter Diagnostics > Page 4640 Shifter Diagnostics TIME ALLOWANCE: **When repairing or diagnosing shifter system the following Labor Operation Numbers should be used:** POLICY: Reimbursable within the provisions of the warranty. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - Differential: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4646 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > CV Boot-Inner Constant Velocity Joint Boot: Service and Repair CV Boot-Inner Removal REMOVAL CAUTION: The inner tripod joints will use a retaining clip inside the housing to keep the spider assembly in the housing. Do not pull on the interconnecting shaft to disengage tripod housing from transmission stub shaft. Removal in this manner will cause damage to the inboard joint sealing boots. 1. Remove the halfshaft requiring boot replacement from the vehicle. 2. Remove large boot clamp (2) that retains inner tripod joint sealing boot to tripod joint housing (3) and discard. Then remove small clamp (1) that retains inner tripod joint sealing boot to interconnecting shaft (5) and discard. Remove the sealing boot (4) from the tripod housing and slide it down the interconnecting shaft. CAUTION: When removing the spider joint from the tripod joint housing, hold the rollers in place on the spider trunnions to prevent the rollers and needle bearings from falling away. 3. Slide the interconnecting shaft and spider assembly (2) out of the tripod joint housing (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > CV Boot-Inner > Page 4653 4. Remove snap ring (3) that retains spider assembly (2) to interconnecting shaft (1). 5. Remove the spider assembly (1) from interconnecting shaft (4). If spider assembly will not come off interconnecting shaft by hand, it can be removed by tapping spider assembly with a brass drift (3). Do not hit the outer tripod bearings in an attempt to remove spider assembly from interconnecting shaft. 6. Slide sealing boot off interconnecting shaft. 7. Thoroughly clean and inspect spider assembly, tripod joint housing, and interconnecting shaft for any signs of excessive wear. If any parts show signs of excessive wear, the halfshaft assembly will require replacement. Component parts of these halfshaft assemblies are not serviceable. Installation INSTALLATION NOTE: The inner tripod joint sealing boots are made from two different types of material. High-temperature applications (close to exhaust system) use silicone rubber whereas standard temperature applications use Hytrel plastic. The silicone sealing boots are soft and pliable. The Hytrel sealing boots are stiff and rigid. The replacement sealing boot MUST BE the same type of material as the sealing boot that was removed. 1. Slide inner tripod joint seal boot retaining clamp onto interconnecting shaft (4). Then slide the replacement inner tripod joint sealing boot (1) onto interconnecting shaft. Inner tripod joint seal boot MUST be positioned on interconnecting shaft, so the raised bead on the inside of the seal boot is in groove (3) on interconnecting shaft. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > CV Boot-Inner > Page 4654 NOTE: The rollers can fall off, use caution when installing the tripod 2. Install spider assembly (1) onto interconnecting shaft with chamfer (3) on spider assembly toward interconnecting shaft (2). 3. Spider assembly (2) must be installed on interconnecting shaft (3) far enough to fully install spider retaining snap ring. If spider assembly will not fully install on interconnecting shaft by hand, it can be installed by tapping the spider body with a brass drift (4). Do not hit the outer tripod bearings in an attempt to install spider assembly on interconnecting shaft. 4. Install the spider assembly (2) to interconnecting shaft retaining snap ring (3) into groove on end of interconnecting shaft. Be sure the snap ring is fully seated into groove on interconnecting shaft (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > CV Boot-Inner > Page 4655 5. Distribute 1/2 the amount of grease provided in the seal boot service package (DO NOT USE ANY OTHER TYPE OF GREASE) into tripod housing. Put the remaining amount into the sealing boot (3). 6. Align tripod housing (1) with spider assembly (2) and then slide tripod housing over spider assembly and interconnecting shaft. 7. Install inner tripod joint seal boot to interconnecting shaft clamp (3) evenly on sealing boot (4). 8. Clamp sealing boot onto interconnecting shaft using Clamp C-4975-A and the following procedure. Place Clamp C-4975-A over bridge of clamp. 9. Tighten nut on Clamp C-4975-A until jaws on tool are closed completely together (2), face to face. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > CV Boot-Inner > Page 4656 CAUTION: Seal must not be dimpled, stretched, or out-of-shape in any way. If seal is NOT shaped correctly, equalize pressure in seal and shape it by hand. 10. Position sealing boot into the tripod (3) retaining groove. Install seal boot retaining clamp (2) evenly on sealing boot (1). CAUTION: The following positioning procedure determines the correct air pressure inside the inner tripod joint assembly prior to clamping the sealing boot to inner tripod joint housing. If this procedure is not done prior to clamping sealing boot to tripod joint housing, boot durability can be adversely affected. CAUTION: When venting the inner tripod joint assembly, use care so inner tripod sealing boot does not get punctured or, in any other way, damaged. If sealing boot is punctured or damaged while being vented, the sealing boot can not be used. 11. Insert a trim stick (4) between the tripod (3) and the sealing boot (1) to vent inner tripod joint assembly. When inserting trim stick between tripod housing and sealing boot, ensure trim stick is held flat and firmly against the tripod housing. If this is not done, damage to the sealing boot can occur. If inner tripod joint has a Hytrel (hard plastic) sealing boot, be sure trim stick is inserted between soft rubber insert and tripod housing, and not the hard plastic sealing boot and soft rubber insert. 12. With trim stick inserted between sealing boot (2) and tripod joint housing (4), position inner tripod joint on halfshaft until correct sealing boot edge to edge length (1) is obtained for type of sealing boot material being used. Then remove the trim stick. 13. With trim stick inserted between sealing boot (2) and tripod housing (4), position inner tripod joint on halfshaft until correct sealing boot edge to edge length (1) is obtained for type of sealing boot material being used. Then remove the trim stick. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > CV Boot-Inner > Page 4657 14. Clamp (1) tripod joint sealing boot (4) to tripod joint (2) using required procedure for type of boot clamp application. If seal boot uses crimp type boot clamp, clamp sealing boot onto tripod housing using Clamp C-4975-A (3). Place Clamp C-4975-A over bridge of clamp (1). 15. Tighten nut on Clamp C-4975-A (3) until jaws on tool (3) are closed completely together (4), face-to-face. 16. If seal boot (3) uses low profile latching type boot clamp, clamp sealing boot onto tripod housing using Clamping Tool, Snap-On(R) YA3050 (2) (or an equivalent). Place prongs of Clamp Locking Tool in the holes of the clamp (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > CV Boot-Inner > Page 4658 17. Squeeze tool together until top band of clamp is latched behind the two tabs (2) on lower band of clamp. 18. Install the halfshaft requiring boot replacement back on the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > CV Boot-Inner > Page 4659 Constant Velocity Joint Boot: Service and Repair CV Boot-Outer Removal REMOVAL 1. Remove halfshaft assembly requiring boot replacement from vehicle. 2. Remove large boot clamp (4) retaining CV joint sealing boot to CV joint housing (3) and discard. Remove small clamp (1) that retains outer CV joint sealing boot to interconnecting shaft (5) and discard. Remove sealing boot (2) from outer CV joint housing and slide it down interconnecting shaft. 3. Wipe away grease to expose outer CV joint and interconnecting shaft. 4. Remove outer CV joint from interconnecting shaft using the following procedure: Support interconnecting shaft in a vise equipped with protective caps on jaws of vise to prevent damage to interconnecting shaft. Then, using a soft-faced hammer (1), sharply hit the end of the CV joint housing to dislodge housing from internal circlip (3) on interconnecting shaft. Then slide outer CV joint off end of interconnecting shaft, joint may have to be tapped off shaft using a soft-faced hammer. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > CV Boot-Inner > Page 4660 5. Remove large circlip (3) from the interconnecting shaft (2) before attempting to remove outer CV joint sealing boot. 6. Slide sealing boot off interconnecting shaft. 7. Thoroughly clean and inspect outer CV joint assembly and interconnecting joint for any signs of excessive wear. If any parts show signs of excessive wear, the halfshaft assembly will require replacement. Component parts of these halfshaft assemblies are not serviceable. Installation INSTALLATION 1. Slide new sealing boot clamp (2) onto interconnecting shaft (4). Slide the outer CV joint assembly sealing boot (1) onto the interconnecting shaft (4). Seal boot MUST be positioned on interconnecting shaft so the raised bead on the inside of the seal boot is in groove on interconnecting shaft. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > CV Boot-Inner > Page 4661 2. Align splines on interconnecting shaft with splines on cross of outer CV joint assembly and start outer CV joint onto interconnecting shaft. 3. Install outer CV joint assembly onto interconnecting shaft by using a soft-faced hammer (1) and tapping end of stub axle (2) (with hub nut (4) installed) until outer CV joint (3) is fully seated on interconnecting shaft. 4. Outer CV joint assembly must be installed on interconnecting shaft until cross (2) of outer CV joint assembly (3) is seated against circlip on interconnecting shaft (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > CV Boot-Inner > Page 4662 5. Distribute 1/2 the amount of grease provided in seal boot service package (DO NOT USE ANY OTHER TYPE OF GREASE) into outer CV joint assembly housing. Put the remaining amount into the sealing boot (4). 6. Install outer CV joint sealing boot to interconnecting shaft clamp evenly on sealing boot. 7. Clamp sealing boot onto interconnecting shaft (2) using crimper, Clamp C-4975-A and the following procedure. Place Clamp C-4975-A (1) over bridge of clamp (3). 8. Tighten nut on Clamp C-4975-A until jaws on tool are closed completely together (2), face to face. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > CV Boot-Inner > Page 4663 CAUTION: Seal must not be dimpled, stretched, or out-of-shape in any way. If seal is NOT shaped correctly, equalize pressure in seal and shape it by hand. 9. Position outer CV joint sealing boot (4) into its retaining groove on outer CV joint housing. Install sealing boot to outer CV joint retaining clamp (1) evenly on sealing boot. 10. Clamp sealing boot onto outer CV joint housing using Clamp C-4975-A (3) and the following procedure. Place Clamp C-4975-A over bridge of clamp (1). 11. Tighten nut on Clamp C-4975-A until jaws on tool are closed completely together (4), face to face. 12. Install the halfshaft requiring boot replacement back on the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Description and Operation > Front Suspension Wheel Bearing: Description and Operation Front Suspension DESCRIPTION The wheel bearing (5) and hub (3) are pressed into the knuckle (1). The wheel bearing is secured in place using a snap ring. One side of the wheel bearing has an integrated magnetic encoder ring for wheel speed sensor usage as equipped. It is important that the wheel speed sensor magnetic encoder ring (dark band) (3) be positioned to the inside of the knuckle or the wheel speed sensor will not operate correctly. The wheel bearing is a Unit 1 type cartridge bearing that requires no maintenance. The wheel bearing can be serviced separately from the hub. The hub supports the driveline halfshaft outer constant velocity (C/V) joint. Each is splined and meshes in the center of the hub. The outer C/V joint is retained to the hub using a nut. The nut is locked to the outer C/V stub shaft using a cotter pin. The hub has five studs pressed into its flange. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Description and Operation > Front Suspension > Page 4668 Wheel Bearing: Description and Operation Rear Suspension DESCRIPTION The rear wheel bearing and wheel mounting hub used on this vehicle are a one-piece sealed unit or hub and bearing assembly. It is permanently lubricated when assembled and is sealed for life. There is no periodic lubrication or maintenance recommended for these units. The hub and bearing (5) is mounted to the trailing link (1). All vehicles have a magnetic encoder integrated into the right rear hub and bearing for speed sense. Vehicles equipped with antilock brakes have a magnetic encoder integrated into both rear hub and bearings. The encoder works with the rear wheel speed sensors to provide wheel speed signal. The sensor mounts by screw to the rear of the front-wheel-drive hub and bearing while the sensor clips to the rear of the all-wheel-drive hub and bearing. The only serviceable components of the hub and bearing are the wheel mounting studs pressed into the hub. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Front Suspension Wheel Bearing: Testing and Inspection Front Suspension WHEEL BEARING AND HUB NOTE: The wheel bearing is designed to last for the life of the vehicle and requires no type of periodic maintenance. The following procedure may be used for diagnosing the condition of the wheel bearing and hub. 1. Remove the wheel and tire assembly, disc brake caliper and brake rotor. 2. Rotate the wheel hub checking for resistance or roughness. Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing. If the bearing exhibits any of these conditions, the hub bearing will require replacement. Do not attempt to disassemble the bearing for repair. If the wheel bearing is disassembled for any reason, it must be replaced. Damaged bearing seals and the resulting excessive grease loss may also require bearing replacement. Moderate grease weeping from the bearing is considered normal and should not require replacement of the wheel bearing. To diagnose a bent hub, measure hub runout. Refer to Brakes and Traction Control/Testing and inspection. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Front Suspension > Page 4671 Wheel Bearing: Testing and Inspection Rear Suspension HUB AND BEARING NOTE: The wheel bearing is designed to last for the life of the vehicle and requires no type of periodic maintenance. The following procedure may be used for diagnosing the condition of the wheel bearing and hub. 1. Remove the wheel and tire assembly, disc brake caliper and brake rotor. 2. Rotate the wheel hub checking for resistance or roughness. Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing. If the bearing exhibits any of these conditions, the hub and bearing will require replacement. Do not attempt to disassemble the bearing for repair. If the wheel bearing is disassembled for any reason, it must be replaced. Damaged bearing seals and the resulting excessive grease loss may also require bearing replacement. Moderate grease seepage from the bearing is considered normal and should not require replacement of the wheel bearing. To diagnose a bent hub, measure hub runout. Refer to Brakes and Traction Control/Testing and Inspection. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension Wheel Bearing: Service and Repair Front Suspension Removal REMOVAL NOTE: The removal and installation of the wheel bearing and hub from the knuckle is only to be done with the knuckle removed from the vehicle. 1. Remove the steering knuckle from the vehicle. 2. Position the locator block (2) for Fixture, Special Tool 9712, as follows: a. For left side knuckles, place the locator block (2) to the left side (4) on the Fixture. The side of the locator block with the angle cut goes downward, toward the Fixture. Install the mounting screws and tighten them to approximately 54 Nm (40 ft. lbs.). b. For right side knuckles, place the locator block (2) to the right side (3) on the Fixture. The side of the locator block with the angle cut goes downward, toward the Fixture. Install the mounting screws and tighten them to approximately 54 Nm (40 ft. lbs.). 3. Install the knuckle in the Fixture as shown, guiding the steering arm (1) to rest on the locator block (3) and the brake caliper mounting bosses on the two Fixture pins (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 4674 4. Place the Fixture (3) with knuckle in an arbor press. 5. Position Remover/Installer, Special Tool 9712-2 (2), in the small end of the hub. Lower the arbor press ram (1) and remove the hub from the wheel bearing and knuckle. The bearing race will normally come out of the wheel bearing with the hub as it is pressed out of the bearing. 6. Remove the knuckle from the Fixture and turn it over. 7. Remove the snap ring (2) from the knuckle using an appropriate pair of snap ring pliers (1). 8. Place the knuckle back in the Fixture (3) in the arbor press ram. 9. Place Installer (2), Special Tool MD-998334, on the outer race of the wheel bearing. Lower the arbor press ram (1) and remove the wheel bearing from the knuckle. 10. Remove the knuckle and tools from arbor press. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 4675 11. If the bearing race is still pressed onto the hub, install the Bearing Splitter (5), Special Tool 1130, between the hub flange and the bearing inner race (4). 12. Place the hub, bearing race and Bearing Splitter in an arbor press. The press support blocks must not obstruct the wheel hub while it is being pressed out of the bearing race. 13. Place Remover/Installer (2), Special Tool 9712-2, in the end of the hub (3). Lower the arbor press ram (1) and remove the hub from the bearing race. NOTE: For installation, refer to Front Suspension Hub Bearing Installation. Installation INSTALLATION CAUTION: When installing the wheel bearing (1) in the knuckle (2) it is important to place the side of bearing with the wheel speed sensor magnetic encoder ring (dark band) (3) in the knuckle first. Otherwise, the wheel speed sensor will not operate correctly. 1. Wipe the bearing bore of the knuckle clean of any grease or dirt with a clean, dry shop towel. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 4676 2. Place the knuckle in an arbor press supporting the knuckle from underneath using Cup (4), Special Tool 6310-1. 3. Place the NEW wheel bearing (5) magnetic encoder ring side down (see above Caution) into the bore of the knuckle. Be sure the wheel bearing is placed squarely into the bore. 4. Place Receiver (3), Special Tool 8498, larger inside diameter end down over the outer race of the wheel bearing. 5. Place Disc (2), Special Tool 6310-2, into top of Receiver 8498. Lower the arbor press ram (1) and press the wheel bearing into the knuckle until it is bottomed in the bore of the knuckle. 6. Remove the knuckle and tools from the arbor press. 7. Install a NEW snap ring (2) in the knuckle using an appropriate pair of snap ring pliers (1). Make sure the snap ring is fully seated. 8. Place the knuckle in an arbor press. Support the knuckle from underneath using Remover/Installer (3), Special Tool MB-990799, smaller end up against the wheel bearing inner race. 9. Place the hub (4) in the wheel bearing making sure it is square with the bearing inner race. 10. Position Remover/Installer, Special Tool 9712-2 (2), in the end of the hub. Lower the arbor press ram (1) and press the hub into the wheel bearing Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 4677 until it bottoms. 11. Remove the knuckle and tools from the press. 12. Verify the hub turns smoothly without rubbing or binding. 13. Install the knuckle on the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 4678 Wheel Bearing: Service and Repair Rear Suspension All-Wheel-Drive ALL-WHEEL-DRIVE NOTE: Before proceeding, refer to REAR SUSPENSION WARNING. 1. Raise and support the vehicle. 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). 3. Remove the cotter pin (2) from the hub nut (3) on the end of the axle half shaft. 4. While a helper applies the brakes to keep the hub (1) from rotating, remove the hub nut (3) and washer (4) from the axle half shaft. 5. Tap the end of the half shaft inward, loosening it from the hub and bearing. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 4679 6. Remove the disc brake caliper (2) lower guide pin bolt (1). CAUTION: When moving rear brake caliper upward, use extreme care not to damage or overextend the flex hose. Damage may occur. 7. Rotate the caliper upward hinging off the upper guide pin bolt. Rotate the caliper upward just enough to allow brake rotor removal. Hang the caliper assembly in this position using wire or a bungee cord. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 4680 8. Remove any clips (2) retaining the brake rotor (3) to the wheel mounting studs. 9. Slide the brake rotor (3) off the hub and bearing (1). 10. Unclip the wheel speed sensor head (1) from the retainer on the rear of the hub and bearing (2). 11. Remove the four bolts (1) securing the hub and bearing (2) to the trailing link. 12. Remove the hub and bearing. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 4681 Front-Wheel-Drive FRONT-WHEEL-DRIVE NOTE: Before proceeding, refer to REAR SUSPENSION WARNING. 1. Raise and support the vehicle. 2. Remove the wheel mounting nuts (3), then the rear tire and wheel assembly. 3. Remove the disc brake caliper (2) lower guide pin bolt (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 4682 CAUTION: When moving rear brake caliper upward, use extreme care not to damage or overextend the flex hose. Damage may occur. 4. Rotate the caliper upward hinging off the upper guide pin bolt. Rotate the caliper upward just enough to allow brake rotor removal. Hang the caliper assembly in this position using wire or a bungee cord. 5. Remove any clips (2) retaining the brake rotor (3) to the wheel mounting studs. 6. Slide the brake rotor (3) off the hub and bearing (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 4683 7. Remove the screw (1) fastening the wheel speed sensor head (3) in the rear of the hub and bearing (2). 8. Remove the four bolts (1) securing the hub and bearing (2) to the trailing link. 9. Remove the hub and bearing. All-Wheel-Drive ALL-WHEEL-DRIVE Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 4684 1. Slide the hub and bearing over the axle half shaft and position it on the brake support plate and trailing link. 2. Install the four bolts (1) securing the hub and bearing (2) to the trailing link. Tighten the bolts to 105 Nm (77 ft. lbs.). 3. Clip the wheel speed sensor head (1) (flat side to bearing rear) into the retainer on the rear of the hub and bearing (2). 4. Slide the brake rotor (3) over the parking brake shoes and onto the hub and bearing (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 4685 5. Rotate the disc brake caliper downward over the brake rotor and lower part of caliper adapter. 6. Install the disc brake caliper (2) lower guide pin bolt (1). Tighten the guide pin bolt to 60 Nm (44 ft. lbs.). 7. Clean all foreign matter from the threads of the half shaft outer C/V joint. 8. Install the washer (4) and hub nut (3) on the end of the half shaft and snug it. 9. While a helper applies the brakes to keep the hub (1) from rotating, tighten the hub nut (3) to 245 Nm (181 ft. lbs.). 10. Insert the cotter pin (2) through the notches in the nut and the hole in half shaft. If the notches in the nut do not line up with the hole in the half shaft, continue to tighten the nut until they do. Do not loosen the nut. 11. Wrap the cotter pin (2) ends tightly around the lock nut. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 4686 12. Install tire and wheel assembly (1). Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 13. Lower the vehicle. 14. Pump the brake pedal several times to ensure the vehicle has a firm brake pedal before moving it. Front-Wheel-Drive FRONT-WHEEL-DRIVE NOTE: If equipped, make sure the wheel speed sensor mount on the rear of the hub and bearing is directed toward the front of the vehicle. 1. Position the hub and bearing on the brake support plate and trailing link. 2. Install the four bolts (1) securing the hub and bearing (2) to the trailing link. Tighten the bolts to 105 Nm (77 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 4687 3. If equipped, install the wheel speed sensor head (3) into the rear of the hub and bearing (2). 4. Install the wheel speed sensor head mounting screw (1). Tighten the screw to 10 Nm (89 in. lbs.). 5. Slide the brake rotor (3) over the parking brake shoes and onto the hub and bearing (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 4688 6. Rotate the disc brake caliper downward over the brake rotor and lower part of caliper adapter. 7. Install the disc brake caliper (2) lower guide pin bolt (1). Tighten the guide pin bolt to 60 Nm (44 ft. lbs.). 8. Install tire and wheel assembly (1). Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 9. Lower the vehicle. 10. Pump the brake pedal several times to ensure the vehicle has a firm brake pedal before moving it. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Hub Nut Tightening Torque ................................................................................................................. .............................................................. 245 Nm (181 ft. lbs.) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications Flywheel: Specifications Flywheel Install and torque the flywheel-to-crankshaft bolts ................................................................................................................................... 95 Nm (70 ft.lbs.) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications > Page 4696 Flywheel: Description and Operation OPERATION The flywheel serves to dampen the engine firing pulses. The heavy weight of the flywheel relative to the rotating mass of the engine components serves to stabilize the flow of power to the remainder of the drivetrain. The crankshaft has the tendency to attempt to speed up and slow down in response to the cylinder firing pulses. The flywheel dampens these impulses by absorbing energy when the crankshaft speeds and releasing the energy back into the system when the crankshaft slows down. On a Dual Mass Flywheel, the additional secondary mass coupled to the transmission lowers the natural frequency of the transmission rotating elements. This decreases the transmission gear rattle. The damper springs between the two flywheel masses replace the clutch disc damper springs and assist in a smooth transfer of torque to the transmission. CAUTION: The Dual Mass Flywheel is serviced as an assembly only and should never be disassembled. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Service and Repair > Removal Flywheel: Service and Repair Removal REMOVAL 1. Remove transaxle. 2. Remove clutch pressure plate and disc. 3. Remove eight (8) flywheel-to-crankshaft bolts (2) and remove flywheel assembly (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Service and Repair > Removal > Page 4699 Flywheel: Service and Repair Installation INSTALLATION 1. Clean the surfaces of the flywheel and pressure plate to make certain that all oil, grease, and rust have been removed. 2. Install and torque the flywheel-to-crankshaft bolts to 95 Nm (70 ft.lbs.). 3. Install clutch pressure plate and disc. 4. Install transaxle assembly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - M/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4706 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - M/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4711 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Manual Transmission Fluid Capacity NV T355 .............................................................................................................................................. ................................................ 2.4-2.7 L (2.5-2.8 Qt) BG6 ..................................................................................................................................................... ............................................................. 2.0 L (2.1 Qt) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 4714 Fluid - M/T: Fluid Type Specifications Manual Transaxle Fluid Manual Fluid ........................................................................................................................................ ............................................ Mopar ATF+4 MS9602 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Service and Repair > BG6 Manual Transaxle Fluid - M/T: Service and Repair BG6 Manual Transaxle Fluid Level Checking FLUID LEVEL CHECKING The fluid required for this transaxle is Mopar(R) ATF+4 (Automatic Transmission Fluid). Use of improper or substitute fluids can cause shift problems and/or transaxle failure. 1. Insure the vehicle is level, remove the fill plug and add fluid until the fluid just starts to trickle out. Fluid Drain And Fill FLUID DRAIN AND FILL NOTE: The fluid required for this transaxle is Mopar(R) ATF+4 (Automatic Transmission Fluid). Use of improper or substitute fluids can cause shift problems and/or transaxle failure. 1. Raise vehicle on hoist. 2. Obtain suitable fluid collection container and place under transaxle. 3. Remove transaxle drain plug (2). Allow fluid to drain into container until empty. 4. Install the drain plug (1) with a new gasket and tighten to 39 Nm (29 ft. lbs.). 5. Remove transaxle fill plug (1). 6. Add the appropriate amount of transaxle fluid to the transaxle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Service and Repair > BG6 Manual Transaxle > Page 4717 Fluid - M/T: Service and Repair T355 Manual Transaxle STANDARD PROCEDURE - FLUID DRAIN AND FILL NOTE: All T355 Manual Transaxles require the use of ATF+4 (Automatic Transmission Fluid). The transaxle fill plug (1) is located on the left side of the transaxle differential area. The fluid level should be within 3/16 inch from the bottom of the transaxle fill hole (vehicle must be level when checking). The transaxle drain plug (2) is located on the lower right side of the transaxle differential housing. Tighten drain plug to 14 Nm (120 in. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > BG6 Manual Transaxle Seals and Gaskets: Service and Repair BG6 Manual Transaxle Removal REMOVAL 1. Remove axle shaft. 2. Insert a flat-blade pry tool (2) at outer edge of axle shaft seal (1). 3. Tap on the pry tool (2) with a small hammer and remove axle shaft seal (1). Installation INSTALLATION 1. Clean axle shaft seal bore of any excess sealant. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > BG6 Manual Transaxle > Page 4722 2. Align (bellhousing side) axle shaft seal with axle shaft seal bore. 3. Install axle seal on Seal Installer 9928 and Handle C-4171 and insert into axle shaft seal bore. 4. Tap seal into position until seated against transaxle case. 5. Align axle shaft seal with axle shaft seal bore. 6. Install (case side) axle seal on Seal Installer 9934 and Handle C-4171 and insert into axle shaft seal bore. 7. Tap seal into position until seated against transaxle case. 8. Install axle shaft. 9. Check transaxle fluid level and adjust as necessary. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > BG6 Manual Transaxle > Page 4723 Seals and Gaskets: Service and Repair T355 Manual Transaxle Removal REMOVAL 1. Remove axle shaft. 2. Insert a flat-blade pry tool (2) at outer edge of axle shaft seal (1). 3. Tap on the pry tool (2) with a small hammer and remove axle shaft seal (1). Installation INSTALLATION 1. Clean axle shaft seal bore of any excess sealant. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > BG6 Manual Transaxle > Page 4724 2. Align (bellhousing side) axle shaft seal with axle shaft seal bore. 3. Install axle seal on Seal Installer 9928 and Handle C-4171 and insert into axle shaft seal bore. 4. Tap seal into position until seated against transaxle case. 5. Align axle shaft seal with axle shaft seal bore. 6. Install (case side) axle seal on Seal Installer 9934 and Handle C-4171 and insert into axle shaft seal bore. 7. Tap seal into position until seated against transaxle case. 8. Install axle shaft. 9. Check transaxle fluid level and adjust as necessary. Removal REMOVAL 1. Remove the transaxle. 2. Remove seal. Installation INSTALLATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > BG6 Manual Transaxle > Page 4725 1. Install input shaft seal (2) using installer 8864 (1). 2. Install the transaxle. Removal REMOVAL It is not necessary to remove the shift shafts from the transaxle to service the shift shaft seals. 1. Using a pick tool, pry up on the shift shaft seal, and remove seal from bore. Installation INSTALLATION 1. Position new shift shaft seal into bore. 2. Install shift shaft seal into bore using an appropriate size deep-well socket. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Description and Operation Transmission Speed Sensor: Description and Operation VEHICLE SPEED SENSOR The Vehicle Speed Sensor (VSS) is a hall effect sensor mounted above the transaxle differential. The sensor is triggered by the ring gear teeth passing below it. The VSS pulse signal to the speedometer/odometer is monitored by the PCM speed control circuitry to determine vehicle speed and to maintain speed control set speed. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Removal Transmission Speed Sensor: Service and Repair Removal REMOVAL 1. Open hood. 2. Remove the air cleaner housing. 3. Disconnect the speed sensor connector. CAUTION: Clean area around speed sensor before removing to prevent dirt from entering the transaxle during speed sensor removal. 4. Remove speed sensor retaining bolt. 5. Remove speed sensor from transaxle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Removal > Page 4732 Transmission Speed Sensor: Service and Repair Installation INSTALLATION 1. Using a NEW O-ring, install the speed sensor to the transaxle. 2. Install the bolt and tighten to 7 Nm (60 in. lbs.). 3. Connect speed sensor connector. 4. Install the air cleaner housing. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > BG6 Manual Transaxle Shifter M/T: Service and Repair BG6 Manual Transaxle Removal REMOVAL 1. Pull up on gearshift knob (1) with moderate force to remove from gearshift mechanism. 2. Remove shifter boot/bezel (3) assembly from console by lifting up at mounting ring area. Installation INSTALLATION 1. Position gearshift boot (3) over the operating lever (2) and apply hand pressure to engage and snap console into place. 2. Position gearshift knob (1) hole over the gearshift mechanism and align the shift pattern. 3. Verify that shift pattern is aligned properly. 4. Strike knob (1) with rubber mallet to engage knob to mechanism. Removal REMOVAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > BG6 Manual Transaxle > Page 4737 1. Pull up on gearshift knob (1) with moderate force to remove from gearshift mechanism. Installation INSTALLATION 1. Position knob hole (1) over the gearshift mechanism and align the shift pattern. 2. Verify that shift pattern is aligned properly. 3. Strike knob (1) with rubber mallet to engage knob to mechanism. Removal REMOVAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > BG6 Manual Transaxle > Page 4738 1. Remove gear shift boot. 2. Remove the center console assembly. Remove rear power window switch (if equipped) and disconnect harness from console. NOTE: Cable is pushed into a rubber grommet. 3. Remove select cable (2) from shift lever (1). 4. Remove shift cable retaining clip (3) and disconnect cable (2) from the shift lever (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > BG6 Manual Transaxle > Page 4739 5. Remove the shifter assembly to riser bolts (3) and remove shifter from vehicle. Installation INSTALLATION 1. Install shifter assembly (1) to riser. Install and tighten bolts (3) to 7 Nm (61 in. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > BG6 Manual Transaxle > Page 4740 2. Install shift cable (2) to shifter lever (1) and secure cable to shifter bracket with clip (3). 3. Install select cable to shifter lever and secure cable to shifter bracket. 4. Install center console assembly. Install rear power window switch (if equipped) and fasten harness to console. 5. Install gearshift boot. 6. Verify that shift pattern is aligned properly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > BG6 Manual Transaxle > Page 4741 Shifter M/T: Service and Repair T355 Manual Transaxle Removal REMOVAL 1. Pull up on gearshift knob (1) with moderate force to remove from gearshift mechanism. 2. Remove shifter boot/bezel (3) assembly from console by lifting up at mounting ring area. Installation INSTALLATION 1. Position gearshift boot (3) over the operating lever (2) and apply hand pressure to engage and snap console into place. 2. Position gearshift knob (1) hole over the gearshift mechanism and align the shift pattern. 3. Verify that shift pattern is aligned properly. 4. Strike knob (1) with rubber mallet to engage knob to mechanism. Removal REMOVAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > BG6 Manual Transaxle > Page 4742 1. Pull up on gearshift knob (1) with moderate force to remove from gearshift mechanism. Installation INSTALLATION 1. Position knob hole (1) over the gearshift mechanism and align the shift pattern. 2. Verify that shift pattern is aligned properly. 3. Strike knob (1) with rubber mallet to engage knob to mechanism. Removal REMOVAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > BG6 Manual Transaxle > Page 4743 1. Remove gear shift boot. 2. Remove the center console assembly. Remove rear power window switch (if equipped) and disconnect harness from console. NOTE: Cable is pushed into a rubber grommet. 3. Remove select cable (2) from shift lever (1). 4. Remove shift cable retaining clip (3) and disconnect cable (2) from the shift lever (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > BG6 Manual Transaxle > Page 4744 5. Remove the shifter assembly to riser bolts (3) and remove shifter from vehicle. Installation INSTALLATION 1. Install shifter assembly (1) to riser. Install and tighten bolts (3) to 7 Nm (61 in. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > BG6 Manual Transaxle > Page 4745 2. Install shift cable (2) to shifter lever (1) and secure cable to shifter bracket with clip (3). 3. Install select cable to shifter lever and secure cable to shifter bracket. 4. Install center console assembly. Install rear power window switch (if equipped) and fasten harness to console. 5. Install gearshift boot. 6. Verify that shift pattern is aligned properly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Selector Shaft, M/T > Component Information > Service and Repair > Selector Shaft Selector Shaft: Service and Repair Selector Shaft Removal REMOVAL 1. Disassemble transaxle. 2. With the transaxle disassembled, remove the select shaft seal. 3. Using snap-ring pliers, remove the snap ring (3) at the select shaft bore. 4. Push the select shaft (2) in the case and remove the select assembly. Installation INSTALLATION 1. Install select shaft to case and install snap ring (3). 2. Install the select shaft seal. 3. Assemble transaxle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Selector Shaft, M/T > Component Information > Service and Repair > Selector Shaft > Page 4751 Selector Shaft: Service and Repair Selector Shaft Bushing Removal REMOVAL 1. Install Slide Hammer C-3752 (1) through the select bushing. 2. Thread nut and washer onto slide hammer. 3. Using the slide hammer, remove the select shaft bushing (2). Installation INSTALLATION 1. Position the replacement select shaft bushing over the crossover shaft bushing bore. 2. Using an appropriate size deep-well socket, install the select shaft bushing into the bushing bore. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Adjustments Shift Cable: Adjustments ADJUSTMENT Increase the (4) distance to eliminate 2nd gear downshift blocking condition (3 - 2, or 4 - 2 blocking). NOTE: Must verify reverse shift after adjusting. Decrease the distance if shifter can not engage reverse. 1. Loosen select lever bracket bolts (2). 2. Adjust gage length fore/aft by pivoting bracket and re-securing. Torque to 21.4 +/- 5.2 Nm. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Service and Repair > BG6 Manual Transaxle Shift Cable: Service and Repair BG6 Manual Transaxle Removal REMOVAL 1. Remove the shifter. 2. Raise hood. 3. Remove the resonator. 4. Remove engine cover. 5. Remove air cleaner assembly. 6. Disconnect both battery cables. 7. Remove battery hold down clamp and bolt, and remove battery. 8. Remove battery tray. 9. Disconnect cables (1) from the shift levers at the transaxle. CAUTION: Pry up with equal force on both sides of shifter cable isolator bushings to avoid damaging cable isolator bushings. 10. Remove cable retaining clips and remove cables (1) from bracket (3). 11. Remove the Occupant Restraint Controller (ORC). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Service and Repair > BG6 Manual Transaxle > Page 4757 12. Remove cable clips at floor pan. 13. Remove cable assembly (1) from vehicle. Installation INSTALLATION CAUTION: Gearshift cable bushings must not be lubricated or the bushings will swell and split. 1. Install cable assembly through floor pan opening until grommet is seated. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Service and Repair > BG6 Manual Transaxle > Page 4758 2. Route transaxle end of cable assembly into engine compartment and over transaxle assembly. 3. Install cables (1) and NEW retaining clips to bracket. 4. Install gearshift cables to mounting bracket and fasten with NEW clips (2). Make sure clips are installed flush to bracket. 5. Connect cables (1) to the shift levers (3) at the transaxle. 6. Install ORC. 7. Install shifter. 8. Install battery tray. 9. Install battery and hold-down clamp. 10. Install the air cleaner assembly. 11. Connect battery cables. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Service and Repair > BG6 Manual Transaxle > Page 4759 Shift Cable: Service and Repair T355 Manual Transaxle Removal REMOVAL 1. Remove the shifter. 2. Raise hood. 3. Remove the resonator. 4. Remove engine cover. 5. Remove air cleaner assembly. 6. Disconnect both battery cables. 7. Remove battery hold down clamp and bolt, and remove battery. 8. Remove battery tray. 9. Disconnect cables (1) from the shift levers at the transaxle (3). CAUTION: Pry up with equal force on both sides of shifter cable isolator bushings to avoid damaging cable isolator bushings. 10. Squeeze cable retaining clips (2) and remove cables from bracket (4). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Service and Repair > BG6 Manual Transaxle > Page 4760 11. Remove the Occupant Restraint Controller (ORC). 12. Squeeze cable retaining clips (2) and remove cables from bracket. 13. Remove cable assembly (1) from vehicle. Installation INSTALLATION CAUTION: Gearshift cable bushings must not be lubricated or the bushings will swell and split. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Service and Repair > BG6 Manual Transaxle > Page 4761 1. Install cable assembly through floor pan opening and secure to floor pan with grommet plate. 2. Route transaxle end of cable assembly into engine compartment and over transaxle assembly. 3. Connect cables (1) to the shift levers (3) at the transaxle. 4. Install cables (1) to bracket (4). 5. Install gearshift cables (1). 6. Install ORC. 7. Install shifter. 8. Install battery tray. 9. Install battery and hold-down clamp. 10. Install the air cleaner assembly. 11. Connect battery cables. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Rail, M/T > Component Information > Service and Repair > Removal Shift Rail: Service and Repair Removal REMOVAL 1. Thread Remover 6786 (1) into shift rail bushing. 2. Install slide hammer C-3752 (2) onto tool. 3. Remove bushing (3) using slide hammer and tool assembly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Rail, M/T > Component Information > Service and Repair > Removal > Page 4766 Shift Rail: Service and Repair Installation INSTALLATION 1. Line up replacement bushing in bore. 2. Using Installer MD998343, tap bushing into bore until flush with the chamfer in the case. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Description and Operation Transmission Speed Sensor: Description and Operation VEHICLE SPEED SENSOR The Vehicle Speed Sensor (VSS) is a hall effect sensor mounted above the transaxle differential. The sensor is triggered by the ring gear teeth passing below it. The VSS pulse signal to the speedometer/odometer is monitored by the PCM speed control circuitry to determine vehicle speed and to maintain speed control set speed. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Removal Transmission Speed Sensor: Service and Repair Removal REMOVAL 1. Open hood. 2. Remove the air cleaner housing. 3. Disconnect the speed sensor connector. CAUTION: Clean area around speed sensor before removing to prevent dirt from entering the transaxle during speed sensor removal. 4. Remove speed sensor retaining bolt. 5. Remove speed sensor from transaxle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Removal > Page 4772 Transmission Speed Sensor: Service and Repair Installation INSTALLATION 1. Using a NEW O-ring, install the speed sensor to the transaxle. 2. Install the bolt and tighten to 7 Nm (60 in. lbs.). 3. Connect speed sensor connector. 4. Install the air cleaner housing. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor Control Module: Technical Service Bulletins Engine Controls - MIL On/DTC P0116/ECT Sensor NUMBER: 18-039-06 GROUP: Vehicle Performance DATE: December 6, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES FOR StarSCAN. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 7.02 SP2 OR HIGHER FOR THIS BULLETIN. SUBJECT: Flash: MIL Illumination DTC P0116 - Engine Coolant Temperature Sensor Performance OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) and the Transmission Control Module (1CM) with new software. CAUTION: VEHICLES EQUIPPED WITH A CVT TRANSMISSION MUST HAVE THE TRANSMISSION CONTROL MODULE (TCM) CHECKED FOR THE LATEST SOFTWARE LEVEL WHENEVER THE PCM SOFTWARE IS UPGRADED. IF NEWER TCM SOFTWARE IS AVAILABLE, IT MUST BE INSTALLED. MODELS: 2007 (PM) Caliber 2007 (MK49) Compass NOTE: This bulletin applies to PM/MK models equipped with a 1.8L, 2.0L or 2.4L gasoline engine (Sales Code EBA, ECN or ED3) and block heater (Sales Code NHK) built before November 20, 2006 (MDH 1120XX). NOTE: If an aftermarket or MOPAR accessory block heater is installed, the same conditions may apply. SYMPTOM/CONDITION: Some customers may experience MIL illumination after using the block heater. No other symptoms will be experienced. The technician may find the following DTC's: ^ P0116 - ENGINE COOLANT TEMPERATURE SENSOR PERFORMANCE DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If MIL illumination with DTC P0116 is present, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 4779 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING **STEP 5n and/or 8h**. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 7.02 SP2 software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. PM/MK Models equipped with a CVT must have the TCM reprogrammed as follows: 6. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. 7. Is the TCM part number recorded in step 6e above, the same as the new p/n shown on the "Flash File List" screen? a. Yes >> No further action is necessary. Proceed to Step 9. b. No >> the TCM will require flash reprogramming, proceed to Step 8. 8. Flash reprogram the TCM as follows: a. From the "Flash File List" screen, select "Download to Scantool". b. Select "Close" after the download is complete, then select "Back". c. Highlight the listed calibration. d. Select "Update Controller". Follow on screen instructions. e. When the update is complete, select "OK". f. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. g. Turn the ignition switch to the OFF position for no less than 15 seconds. h. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 4780 CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the TCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. ** NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 9. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 Control Module: Customer Interest A/T - MIL ON Possible DTC P2004 NUMBER: 18-032-07 GROUP: Vehicle Performance DATE: May 16, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 7.04 SPI OR HIGHER FOR THIS BULLETIN. SUBJECT: Flash: MIL Illumination with DIG P2004 OVERVIEW: This bulletin involves selectively erasing and reprogramming the GPEC Powertrain Control Module (PCM) with new software and replacing the intake manifold as required. CAUTION: VEHICLES EQUIPPED WITH A CVT TRANSMISSION MUST HAVE THE TRANSMISSION CONTROL MODULE (TCM) CHECKED FOR THE LATEST SOFTWARE LEVEL WHENEVER THE PCM SOFTWARE IS UPGRADED. IF NEWER TCM SOFTWARE IS AVAILABLE, IT MUST BE INSTALLED. MODELS: 2007-2008 (JS) Avenger 2007 (JS) Sebring 2008 (J527) Sebring Convertible 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to models equipped with a 1.8L, 2.0L or 2.4L gasoline engine (Sales Code EBA, ECN or ED3) as follows: Flash portion applies to PM/MK models built through April 21, 2007 (MDH 0421 XX) and JS models built through May 15, 2007 (0515XX). The Intake Manifold Replacement portion applies to models built through March 22, 2007 (MDHO322XX). SYMPTOM/CONDITION: Some customers may experience MIL Illumination with no other symptoms. The condition may occur intermittently. Further investigation by the technician may find DTC P2004 - Intake Manifold Runner Control Stuck Open as the cause for MIL Illumination. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine Systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Perform the standard diagnostic procedures for DIG P2004. If the diagnostics do not lead to the failure, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 4790 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and/or 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 7.04 SPI software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service> StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options d. Select "ECU Flash e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 4791 j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. m. Turn the ignition switch to the OFF position for no less than 15 seconds. n. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING 5n OR 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. PM/MK Models equipped with a CVT must have the TCM reprogrammed as follows: 6. Using the StarSCAN(R) at the "Home screen": a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. 7. Is the TCM part number recorded in step 6e above, the same as the new pin shown on the "Flash File List" screen? a. Yes > No further action is necessary. Proceed to Step 9. b. No > the TCM will require flash reprogramming, proceed to Step 8. 8. Flash reprogram the TCM as follows: a. From the "Flash File List screen, select "Download to Scantool". b. Select "Close" after the download is complete, then select "Back". c. Highlight the listed calibration. d. Select "Update Controller". Follow on screen instructions. e. When the update is complete, select "OK". f. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. g. Turn the ignition switch to the OFF position for no less than 15 seconds. h. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP Sn and 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the TCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list.** Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 4792 NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig.1). 1. Vehicles built through March 22, 2007 will require a new Intake Manifold pn 04884495AF. Following the procedures listed in DealerCONNECT > TechCONNECT replace the intake manifold. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B Technical Service Bulletin # 18-019-06 Date: 060607 A/T Controls - MIL ON/DTC's P0602/P167A or P161B NUMBER: 18-019-06 GROUP: Vehicle Performance DATE: June 7, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: Flash: MIL Illumination - DTC's P0602, P167A, or P161B OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (TCM) with new software and the Powertrain Control Module (PCM) with new software. WARNING: BOTH CONTROLLERS (TCM AND PCM) MUST BE REPROGRAMMED. THIS UPDATE MUST BE COMPLETED AS A COORDINATED CHANGE. IF THE PCM IS NOT UPDATED, MIL ILLUMINATION CAN OCCUR AND DTC U1424 (IMPLAUSIBLE ENGINE TORQUE MESSAGE RECEIVED) WILL BE RECORDED IN THE TCM. MODELS: 2007 (PM) Caliber NOTE: This bulletin applies to vehicles equipped with a Continuously Variable Transmission (CVT), (sales code DAV), built on or before June 1, 2006 (MDH 0601XX). SYMPTOM/CONDITION: The customer may experience Malfunction Indicator Lamp (MIL) illumination. The technician may find the following Diagnostic Trouble Codes (DTC's) in the TCM: ^ P0602-Control Module Programming Error/Not Programmed ^ P167A-Calibration Mismatch ^ P161B-Battery Disconnect / TCM Internal DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes MIL Illumination and the technician finds any of the DTC's listed above, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B > Page 4797 SPECIAL TOOLS / EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. TCM - Repair Procedure - Using the Internet to Retrieve the Flash File NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 6.06 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old TCM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B > Page 4798 b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". I. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. NOTE: Due to the TCM/PCM programming procedure, a DTC may be set in other modules (BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTC's". Press "Clear All Stored DTC's" if there are any DTC's shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 6. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). PCM Repair Procedure - Using the Internet to Retrieve the Flash File CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 6.06 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B > Page 4799 StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the PCM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. m. Turn the ignition switch to the OFF position for no less than 15 seconds. n. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 6. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 Control Module: All Technical Service Bulletins A/T - MIL ON Possible DTC P2004 NUMBER: 18-032-07 GROUP: Vehicle Performance DATE: May 16, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 7.04 SPI OR HIGHER FOR THIS BULLETIN. SUBJECT: Flash: MIL Illumination with DIG P2004 OVERVIEW: This bulletin involves selectively erasing and reprogramming the GPEC Powertrain Control Module (PCM) with new software and replacing the intake manifold as required. CAUTION: VEHICLES EQUIPPED WITH A CVT TRANSMISSION MUST HAVE THE TRANSMISSION CONTROL MODULE (TCM) CHECKED FOR THE LATEST SOFTWARE LEVEL WHENEVER THE PCM SOFTWARE IS UPGRADED. IF NEWER TCM SOFTWARE IS AVAILABLE, IT MUST BE INSTALLED. MODELS: 2007-2008 (JS) Avenger 2007 (JS) Sebring 2008 (J527) Sebring Convertible 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to models equipped with a 1.8L, 2.0L or 2.4L gasoline engine (Sales Code EBA, ECN or ED3) as follows: Flash portion applies to PM/MK models built through April 21, 2007 (MDH 0421 XX) and JS models built through May 15, 2007 (0515XX). The Intake Manifold Replacement portion applies to models built through March 22, 2007 (MDHO322XX). SYMPTOM/CONDITION: Some customers may experience MIL Illumination with no other symptoms. The condition may occur intermittently. Further investigation by the technician may find DTC P2004 - Intake Manifold Runner Control Stuck Open as the cause for MIL Illumination. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine Systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Perform the standard diagnostic procedures for DIG P2004. If the diagnostics do not lead to the failure, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 4805 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and/or 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 7.04 SPI software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service> StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options d. Select "ECU Flash e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 4806 j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. m. Turn the ignition switch to the OFF position for no less than 15 seconds. n. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING 5n OR 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. PM/MK Models equipped with a CVT must have the TCM reprogrammed as follows: 6. Using the StarSCAN(R) at the "Home screen": a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. 7. Is the TCM part number recorded in step 6e above, the same as the new pin shown on the "Flash File List" screen? a. Yes > No further action is necessary. Proceed to Step 9. b. No > the TCM will require flash reprogramming, proceed to Step 8. 8. Flash reprogram the TCM as follows: a. From the "Flash File List screen, select "Download to Scantool". b. Select "Close" after the download is complete, then select "Back". c. Highlight the listed calibration. d. Select "Update Controller". Follow on screen instructions. e. When the update is complete, select "OK". f. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. g. Turn the ignition switch to the OFF position for no less than 15 seconds. h. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP Sn and 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the TCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list.** Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 4807 NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig.1). 1. Vehicles built through March 22, 2007 will require a new Intake Manifold pn 04884495AF. Following the procedures listed in DealerCONNECT > TechCONNECT replace the intake manifold. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B Technical Service Bulletin # 18-019-06 Date: 060607 A/T Controls - MIL ON/DTC's P0602/P167A or P161B NUMBER: 18-019-06 GROUP: Vehicle Performance DATE: June 7, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: Flash: MIL Illumination - DTC's P0602, P167A, or P161B OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (TCM) with new software and the Powertrain Control Module (PCM) with new software. WARNING: BOTH CONTROLLERS (TCM AND PCM) MUST BE REPROGRAMMED. THIS UPDATE MUST BE COMPLETED AS A COORDINATED CHANGE. IF THE PCM IS NOT UPDATED, MIL ILLUMINATION CAN OCCUR AND DTC U1424 (IMPLAUSIBLE ENGINE TORQUE MESSAGE RECEIVED) WILL BE RECORDED IN THE TCM. MODELS: 2007 (PM) Caliber NOTE: This bulletin applies to vehicles equipped with a Continuously Variable Transmission (CVT), (sales code DAV), built on or before June 1, 2006 (MDH 0601XX). SYMPTOM/CONDITION: The customer may experience Malfunction Indicator Lamp (MIL) illumination. The technician may find the following Diagnostic Trouble Codes (DTC's) in the TCM: ^ P0602-Control Module Programming Error/Not Programmed ^ P167A-Calibration Mismatch ^ P161B-Battery Disconnect / TCM Internal DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes MIL Illumination and the technician finds any of the DTC's listed above, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B > Page 4812 SPECIAL TOOLS / EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. TCM - Repair Procedure - Using the Internet to Retrieve the Flash File NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 6.06 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old TCM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B > Page 4813 b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". I. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. NOTE: Due to the TCM/PCM programming procedure, a DTC may be set in other modules (BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTC's". Press "Clear All Stored DTC's" if there are any DTC's shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 6. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). PCM Repair Procedure - Using the Internet to Retrieve the Flash File CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 6.06 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B > Page 4814 StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the PCM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. m. Turn the ignition switch to the OFF position for no less than 15 seconds. n. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 6. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Description and Operation Transmission Speed Sensor: Description and Operation VEHICLE SPEED SENSOR The Vehicle Speed Sensor (VSS) is a hall effect sensor mounted above the transaxle differential. The sensor is triggered by the ring gear teeth passing below it. The VSS pulse signal to the speedometer/odometer is monitored by the PCM speed control circuitry to determine vehicle speed and to maintain speed control set speed. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Removal Transmission Speed Sensor: Service and Repair Removal REMOVAL 1. Open hood. 2. Remove the air cleaner housing. 3. Disconnect the speed sensor connector. CAUTION: Clean area around speed sensor before removing to prevent dirt from entering the transaxle during speed sensor removal. 4. Remove speed sensor retaining bolt. 5. Remove speed sensor from transaxle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Removal > Page 4822 Transmission Speed Sensor: Service and Repair Installation INSTALLATION 1. Using a NEW O-ring, install the speed sensor to the transaxle. 2. Install the bolt and tighten to 7 Nm (60 in. lbs.). 3. Connect speed sensor connector. 4. Install the air cleaner housing. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Differential, Transfer Case > Differential Fluid Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - Transfer Case: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Differential, Transfer Case > Differential Fluid Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4829 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - Transfer Case: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4834 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor Control Module: Technical Service Bulletins Engine Controls - MIL On/DTC P0116/ECT Sensor NUMBER: 18-039-06 GROUP: Vehicle Performance DATE: December 6, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES FOR StarSCAN. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 7.02 SP2 OR HIGHER FOR THIS BULLETIN. SUBJECT: Flash: MIL Illumination DTC P0116 - Engine Coolant Temperature Sensor Performance OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) and the Transmission Control Module (1CM) with new software. CAUTION: VEHICLES EQUIPPED WITH A CVT TRANSMISSION MUST HAVE THE TRANSMISSION CONTROL MODULE (TCM) CHECKED FOR THE LATEST SOFTWARE LEVEL WHENEVER THE PCM SOFTWARE IS UPGRADED. IF NEWER TCM SOFTWARE IS AVAILABLE, IT MUST BE INSTALLED. MODELS: 2007 (PM) Caliber 2007 (MK49) Compass NOTE: This bulletin applies to PM/MK models equipped with a 1.8L, 2.0L or 2.4L gasoline engine (Sales Code EBA, ECN or ED3) and block heater (Sales Code NHK) built before November 20, 2006 (MDH 1120XX). NOTE: If an aftermarket or MOPAR accessory block heater is installed, the same conditions may apply. SYMPTOM/CONDITION: Some customers may experience MIL illumination after using the block heater. No other symptoms will be experienced. The technician may find the following DTC's: ^ P0116 - ENGINE COOLANT TEMPERATURE SENSOR PERFORMANCE DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If MIL illumination with DTC P0116 is present, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 4842 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING **STEP 5n and/or 8h**. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 7.02 SP2 software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. PM/MK Models equipped with a CVT must have the TCM reprogrammed as follows: 6. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. 7. Is the TCM part number recorded in step 6e above, the same as the new p/n shown on the "Flash File List" screen? a. Yes >> No further action is necessary. Proceed to Step 9. b. No >> the TCM will require flash reprogramming, proceed to Step 8. 8. Flash reprogram the TCM as follows: a. From the "Flash File List" screen, select "Download to Scantool". b. Select "Close" after the download is complete, then select "Back". c. Highlight the listed calibration. d. Select "Update Controller". Follow on screen instructions. e. When the update is complete, select "OK". f. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. g. Turn the ignition switch to the OFF position for no less than 15 seconds. h. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 4843 CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the TCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. ** NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 9. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 Control Module: Customer Interest A/T - MIL ON Possible DTC P2004 NUMBER: 18-032-07 GROUP: Vehicle Performance DATE: May 16, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 7.04 SPI OR HIGHER FOR THIS BULLETIN. SUBJECT: Flash: MIL Illumination with DIG P2004 OVERVIEW: This bulletin involves selectively erasing and reprogramming the GPEC Powertrain Control Module (PCM) with new software and replacing the intake manifold as required. CAUTION: VEHICLES EQUIPPED WITH A CVT TRANSMISSION MUST HAVE THE TRANSMISSION CONTROL MODULE (TCM) CHECKED FOR THE LATEST SOFTWARE LEVEL WHENEVER THE PCM SOFTWARE IS UPGRADED. IF NEWER TCM SOFTWARE IS AVAILABLE, IT MUST BE INSTALLED. MODELS: 2007-2008 (JS) Avenger 2007 (JS) Sebring 2008 (J527) Sebring Convertible 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to models equipped with a 1.8L, 2.0L or 2.4L gasoline engine (Sales Code EBA, ECN or ED3) as follows: Flash portion applies to PM/MK models built through April 21, 2007 (MDH 0421 XX) and JS models built through May 15, 2007 (0515XX). The Intake Manifold Replacement portion applies to models built through March 22, 2007 (MDHO322XX). SYMPTOM/CONDITION: Some customers may experience MIL Illumination with no other symptoms. The condition may occur intermittently. Further investigation by the technician may find DTC P2004 - Intake Manifold Runner Control Stuck Open as the cause for MIL Illumination. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine Systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Perform the standard diagnostic procedures for DIG P2004. If the diagnostics do not lead to the failure, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 4853 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and/or 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 7.04 SPI software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service> StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options d. Select "ECU Flash e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 4854 j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. m. Turn the ignition switch to the OFF position for no less than 15 seconds. n. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING 5n OR 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. PM/MK Models equipped with a CVT must have the TCM reprogrammed as follows: 6. Using the StarSCAN(R) at the "Home screen": a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. 7. Is the TCM part number recorded in step 6e above, the same as the new pin shown on the "Flash File List" screen? a. Yes > No further action is necessary. Proceed to Step 9. b. No > the TCM will require flash reprogramming, proceed to Step 8. 8. Flash reprogram the TCM as follows: a. From the "Flash File List screen, select "Download to Scantool". b. Select "Close" after the download is complete, then select "Back". c. Highlight the listed calibration. d. Select "Update Controller". Follow on screen instructions. e. When the update is complete, select "OK". f. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. g. Turn the ignition switch to the OFF position for no less than 15 seconds. h. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP Sn and 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the TCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list.** Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 4855 NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig.1). 1. Vehicles built through March 22, 2007 will require a new Intake Manifold pn 04884495AF. Following the procedures listed in DealerCONNECT > TechCONNECT replace the intake manifold. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B Technical Service Bulletin # 18-019-06 Date: 060607 A/T Controls - MIL ON/DTC's P0602/P167A or P161B NUMBER: 18-019-06 GROUP: Vehicle Performance DATE: June 7, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: Flash: MIL Illumination - DTC's P0602, P167A, or P161B OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (TCM) with new software and the Powertrain Control Module (PCM) with new software. WARNING: BOTH CONTROLLERS (TCM AND PCM) MUST BE REPROGRAMMED. THIS UPDATE MUST BE COMPLETED AS A COORDINATED CHANGE. IF THE PCM IS NOT UPDATED, MIL ILLUMINATION CAN OCCUR AND DTC U1424 (IMPLAUSIBLE ENGINE TORQUE MESSAGE RECEIVED) WILL BE RECORDED IN THE TCM. MODELS: 2007 (PM) Caliber NOTE: This bulletin applies to vehicles equipped with a Continuously Variable Transmission (CVT), (sales code DAV), built on or before June 1, 2006 (MDH 0601XX). SYMPTOM/CONDITION: The customer may experience Malfunction Indicator Lamp (MIL) illumination. The technician may find the following Diagnostic Trouble Codes (DTC's) in the TCM: ^ P0602-Control Module Programming Error/Not Programmed ^ P167A-Calibration Mismatch ^ P161B-Battery Disconnect / TCM Internal DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes MIL Illumination and the technician finds any of the DTC's listed above, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B > Page 4860 SPECIAL TOOLS / EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. TCM - Repair Procedure - Using the Internet to Retrieve the Flash File NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 6.06 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old TCM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B > Page 4861 b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". I. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. NOTE: Due to the TCM/PCM programming procedure, a DTC may be set in other modules (BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTC's". Press "Clear All Stored DTC's" if there are any DTC's shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 6. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). PCM Repair Procedure - Using the Internet to Retrieve the Flash File CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 6.06 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B > Page 4862 StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the PCM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. m. Turn the ignition switch to the OFF position for no less than 15 seconds. n. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 6. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 Control Module: All Technical Service Bulletins A/T - MIL ON Possible DTC P2004 NUMBER: 18-032-07 GROUP: Vehicle Performance DATE: May 16, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 7.04 SPI OR HIGHER FOR THIS BULLETIN. SUBJECT: Flash: MIL Illumination with DIG P2004 OVERVIEW: This bulletin involves selectively erasing and reprogramming the GPEC Powertrain Control Module (PCM) with new software and replacing the intake manifold as required. CAUTION: VEHICLES EQUIPPED WITH A CVT TRANSMISSION MUST HAVE THE TRANSMISSION CONTROL MODULE (TCM) CHECKED FOR THE LATEST SOFTWARE LEVEL WHENEVER THE PCM SOFTWARE IS UPGRADED. IF NEWER TCM SOFTWARE IS AVAILABLE, IT MUST BE INSTALLED. MODELS: 2007-2008 (JS) Avenger 2007 (JS) Sebring 2008 (J527) Sebring Convertible 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to models equipped with a 1.8L, 2.0L or 2.4L gasoline engine (Sales Code EBA, ECN or ED3) as follows: Flash portion applies to PM/MK models built through April 21, 2007 (MDH 0421 XX) and JS models built through May 15, 2007 (0515XX). The Intake Manifold Replacement portion applies to models built through March 22, 2007 (MDHO322XX). SYMPTOM/CONDITION: Some customers may experience MIL Illumination with no other symptoms. The condition may occur intermittently. Further investigation by the technician may find DTC P2004 - Intake Manifold Runner Control Stuck Open as the cause for MIL Illumination. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine Systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Perform the standard diagnostic procedures for DIG P2004. If the diagnostics do not lead to the failure, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 4868 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and/or 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 7.04 SPI software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service> StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options d. Select "ECU Flash e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 4869 j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. m. Turn the ignition switch to the OFF position for no less than 15 seconds. n. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING 5n OR 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. PM/MK Models equipped with a CVT must have the TCM reprogrammed as follows: 6. Using the StarSCAN(R) at the "Home screen": a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. 7. Is the TCM part number recorded in step 6e above, the same as the new pin shown on the "Flash File List" screen? a. Yes > No further action is necessary. Proceed to Step 9. b. No > the TCM will require flash reprogramming, proceed to Step 8. 8. Flash reprogram the TCM as follows: a. From the "Flash File List screen, select "Download to Scantool". b. Select "Close" after the download is complete, then select "Back". c. Highlight the listed calibration. d. Select "Update Controller". Follow on screen instructions. e. When the update is complete, select "OK". f. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. g. Turn the ignition switch to the OFF position for no less than 15 seconds. h. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP Sn and 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the TCM programming procedure, a DTC may be set in other modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list.** Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 4870 NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig.1). 1. Vehicles built through March 22, 2007 will require a new Intake Manifold pn 04884495AF. Following the procedures listed in DealerCONNECT > TechCONNECT replace the intake manifold. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B Technical Service Bulletin # 18-019-06 Date: 060607 A/T Controls - MIL ON/DTC's P0602/P167A or P161B NUMBER: 18-019-06 GROUP: Vehicle Performance DATE: June 7, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: Flash: MIL Illumination - DTC's P0602, P167A, or P161B OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (TCM) with new software and the Powertrain Control Module (PCM) with new software. WARNING: BOTH CONTROLLERS (TCM AND PCM) MUST BE REPROGRAMMED. THIS UPDATE MUST BE COMPLETED AS A COORDINATED CHANGE. IF THE PCM IS NOT UPDATED, MIL ILLUMINATION CAN OCCUR AND DTC U1424 (IMPLAUSIBLE ENGINE TORQUE MESSAGE RECEIVED) WILL BE RECORDED IN THE TCM. MODELS: 2007 (PM) Caliber NOTE: This bulletin applies to vehicles equipped with a Continuously Variable Transmission (CVT), (sales code DAV), built on or before June 1, 2006 (MDH 0601XX). SYMPTOM/CONDITION: The customer may experience Malfunction Indicator Lamp (MIL) illumination. The technician may find the following Diagnostic Trouble Codes (DTC's) in the TCM: ^ P0602-Control Module Programming Error/Not Programmed ^ P167A-Calibration Mismatch ^ P161B-Battery Disconnect / TCM Internal DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes MIL Illumination and the technician finds any of the DTC's listed above, perform the Repair Procedure. PARTS REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B > Page 4875 SPECIAL TOOLS / EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. TCM - Repair Procedure - Using the Internet to Retrieve the Flash File NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 6.06 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old TCM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B > Page 4876 b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". I. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. NOTE: Due to the TCM/PCM programming procedure, a DTC may be set in other modules (BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTC's". Press "Clear All Stored DTC's" if there are any DTC's shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 6. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). PCM Repair Procedure - Using the Internet to Retrieve the Flash File CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 6.06 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-019-06 > Jun > 06 > A/T Controls - MIL ON/DTC's P0602/P167A or P161B > Page 4877 StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the PCM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. m. Turn the ignition switch to the OFF position for no less than 15 seconds. n. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 6. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Description and Operation Transmission Speed Sensor: Description and Operation VEHICLE SPEED SENSOR The Vehicle Speed Sensor (VSS) is a hall effect sensor mounted above the transaxle differential. The sensor is triggered by the ring gear teeth passing below it. The VSS pulse signal to the speedometer/odometer is monitored by the PCM speed control circuitry to determine vehicle speed and to maintain speed control set speed. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Removal Transmission Speed Sensor: Service and Repair Removal REMOVAL 1. Open hood. 2. Remove the air cleaner housing. 3. Disconnect the speed sensor connector. CAUTION: Clean area around speed sensor before removing to prevent dirt from entering the transaxle during speed sensor removal. 4. Remove speed sensor retaining bolt. 5. Remove speed sensor from transaxle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Removal > Page 4885 Transmission Speed Sensor: Service and Repair Installation INSTALLATION 1. Using a NEW O-ring, install the speed sensor to the transaxle. 2. Install the bolt and tighten to 7 Nm (60 in. lbs.). 3. Connect speed sensor connector. 4. Install the air cleaner housing. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > F50 > Feb > 07 > Recall - ABS Module Reprogramming Technical Service Bulletin # F50 Date: 070212 Recall - ABS Module Reprogramming February 2007 Dealer Service Instructions for: Safety Recall F50 Reprogram ABS Control Module Models 2007 (LX) Chrysler 300, Dodge Charger and Magnum - built from September 7, 2006 through November 18, 2006 (MDH 090701 - 111801). 2007 (JS) Chrysler Sebring - built from October 10, 2006 through November 15, 2006 (MDH 101019 - 111509). 2007 (PM) Dodge Caliber - built from September 7, 2006 through November 18, 2006 (MDH 090707 - 111801). 2007 (MK49) Jeep(R) Compass - built from September 7, 2006 through November 18, 2006 (MDH 090707 - 111801). 2007 (MK74) Jeep Patriot - built from September 7, 2006 through November 18, 2006 (MDH 090707 - 111801). 2007 (WK) Jeep Grand Cherokee - built from October 18, 2006 through December 6, 2006 (MDH 101813 - 120606). 2007 (XK) Jeep Commander - built from October 18, 2006 through December 6, 2006 (MDH 101813 - 120606). 2007 (KJ) Jeep Liberty - built from September 18, 2006 through November 30, 2006 (MDH 091807 - 113018). 2007 (KA) Dodge Nitro - built from September 18, 2006 through November 30, 2006 (MDH 091807 - 113018). 2007 (JK) Jeep Wrangler - built from November 9, 2006 through December 8, 2006 (MDH 110914 120811). NOTE: This recall applies only to the above vehicles equipped with an ESP/ABS system (sales code BNB, BRF, BRY, BR1 or BR3). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The software programmed into the Anti-Lock Brake System (ABS) control module on about 50,600 of the above vehicles may cause the rear brakes to lock up during certain braking conditions. This could result in a loss of vehicle control and cause a crash without warning. Repair The ABS control module must be reprogrammed (flashed). Parts Information No parts are required to perform this service procedure. Special Tools Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > F50 > Feb > 07 > Recall - ABS Module Reprogramming > Page 4896 The existing special tools may be required to perform this repair. NOTE: The StarSCAN and the Star Mobile scan tools must be at version 7.03 or higher before this procedure can be performed. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is shown. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > F50 > Feb > 07 > Recall - ABS Module Reprogramming > Page 4897 The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure NOTE: Reprogramming of the ABS Control Module can be performed using the StarSCAN scan tool or the StarMOBILE scan tool. A. Reprogram the ABS Control Module Using StarSCAN NOTE: The StarSCAN tool must be at version 7.03 or higher before this procedure can be performed. The software release level is visible in the blue header at the top of the StarSCAN screen. 1. Open the hood and install a battery charger. Verify that the charging rate provides approximately 13.5 volts. 2. Use the following procedure to determine the ABS Control Module software part number: a. Connect the StarSCAN to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. b. Power ON the StarSCAN. c. From the StarSCAN Home Screen, select "ECU View". d. From the StarSCAN ECU View Screen, select "ABS" from the list of modules. e. Select "More Options" and then select "ECU Flash". f. Record the part number displayed at the top of the "Flash ABS" screen for later reference. 3. Connect the CH9410 ethernet cable to the StarSCAN and the dealer's network drop. 4. Select "Browse for New File" and follow the on screen instructions. 5. Highlight the calibration and then select "Download to Scantool". 6. Select "Close" after the download is complete, disconnect the ethernet cable from the scan tool and then select "Back". 7. Highlight the listed calibration. 8. Select "Update Controller" and follow the screen instructions. 9. When the ABS control module update is complete, select "OK". 10. Verify the part number (resident flash file) at the top of the screen has updated to the new part number. 11. After completing the ABS control module reprogramming, clear all Diagnostic Trouble Codes (DTC's) using the following procedure: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > F50 > Feb > 07 > Recall - ABS Module Reprogramming > Page 4898 a. Return to the "Main Menu" (Home Page). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's" and follow the screen prompts. 12. Disconnect and remove the StarSCAN and battery charger from the vehicle. B. Reprogram the ABS Control Module Using StarMOBILE NOTE: The StarMOBILE scan tool must be at version 7.03 or higher before this procedure can be performed. 1. Open the hood and install a battery charger. Verify that the charging rate provides approximately 13.5 volts. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. Connect the CH9410 ethernet cable to the StarMOBILE and the dealer's network drop. 5. From the desktop, launch the "StarMOBILE Desktop Client" software. 6. From the main menu on the StarMOBILE, select "System Status". 7. Establish a connection with the StarMOBILE scan tool. 8. Select "Flash Download". 9. Select "Next" and then enter your ID and password. 10. Enter the vehicle information (manually or use the automatic function). 11. Highlight the required flash file and select "Download to Client". 12. Select "BACK" then select "ECU View". 13. Select "ABS Antilock Brakes". 14. Select "More Options". 15. Select "ECU Flash". 16. Select "Manage Files". 17. Highlight downloaded flash file. 18. Select "Copy to SM Devise" and then follow the screen prompts. 19. Disconnect the ethernet cable from the StarMOBILE scan tool. 20. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 21. From the "System Status" screen press the "Exit" button. 22. From the "Main Menu" select "Enter Standalone Diagnostic Mode". 23. Select "ECU View" and press the select button. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > F50 > Feb > 07 > Recall - ABS Module Reprogramming > Page 4899 24. Highlight "ABS" and press the select button. 25. Select "Flash ECU" and press the select button. 26. Verify the file number on the screen. If correct, press the select button and follow the screen prompts. 27. When the flash is complete, press the "OK" button. 28. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Return to the "Main Menu" (Home Page). b. From the "Home" screen, select "System View" and then select "All DTC's". c. Select the "Clear All Stored DTC's" and follow screen prompts. 29. Disconnect the StarMOBILE scan tool and battery charger from the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > F50 > Feb > 07 > Recall - ABS Module Reprogramming > Page 4900 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > NHTSA06V493000 > Dec > 06 > Recall 06V493000: ABS Control Module Software Update Electronic Brake Control Module: Recalls Recall 06V493000: ABS Control Module Software Update MAKE/MODELS: MODEL/BUILD YEARS: Chrysler/300 2007 Chrysler/Sebring 2007 Dodge/Caliber 2007 Dodge/Charger 2007 Dodge/Magnum 2007 Dodge/Nitro 2007 Jeep/Commander 2007 Jeep/Compass 2007 Jeep/Grand Cherokee 2007 Jeep/Liberty 2007 Jeep/Wrangler 2007 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 06V493000 MFG'S REPORT DATE: December 22, 2006 COMPONENT: Service Brakes, Hydraulic: Antilock: Control Unit/Module POTENTIAL NUMBER OF UNITS AFFECTED: 62369 SUMMARY: On certain vehicles, the Antilock Brake System (ABS) control module software may cause the rear brakes to lock up during certain braking conditions. CONSEQUENCE: This could result in a loss of vehicle control and cause a crash without warning. REMEDY: Dealers will reprogram the ABS electronic control unit. The recall is expected to begin during February 2007. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. F50. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > F50 > Feb > 07 > Recall - ABS Module Reprogramming Technical Service Bulletin # F50 Date: 070212 Recall - ABS Module Reprogramming February 2007 Dealer Service Instructions for: Safety Recall F50 Reprogram ABS Control Module Models 2007 (LX) Chrysler 300, Dodge Charger and Magnum - built from September 7, 2006 through November 18, 2006 (MDH 090701 - 111801). 2007 (JS) Chrysler Sebring - built from October 10, 2006 through November 15, 2006 (MDH 101019 - 111509). 2007 (PM) Dodge Caliber - built from September 7, 2006 through November 18, 2006 (MDH 090707 - 111801). 2007 (MK49) Jeep(R) Compass - built from September 7, 2006 through November 18, 2006 (MDH 090707 - 111801). 2007 (MK74) Jeep Patriot - built from September 7, 2006 through November 18, 2006 (MDH 090707 - 111801). 2007 (WK) Jeep Grand Cherokee - built from October 18, 2006 through December 6, 2006 (MDH 101813 - 120606). 2007 (XK) Jeep Commander - built from October 18, 2006 through December 6, 2006 (MDH 101813 - 120606). 2007 (KJ) Jeep Liberty - built from September 18, 2006 through November 30, 2006 (MDH 091807 - 113018). 2007 (KA) Dodge Nitro - built from September 18, 2006 through November 30, 2006 (MDH 091807 - 113018). 2007 (JK) Jeep Wrangler - built from November 9, 2006 through December 8, 2006 (MDH 110914 120811). NOTE: This recall applies only to the above vehicles equipped with an ESP/ABS system (sales code BNB, BRF, BRY, BR1 or BR3). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The software programmed into the Anti-Lock Brake System (ABS) control module on about 50,600 of the above vehicles may cause the rear brakes to lock up during certain braking conditions. This could result in a loss of vehicle control and cause a crash without warning. Repair The ABS control module must be reprogrammed (flashed). Parts Information No parts are required to perform this service procedure. Special Tools Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > F50 > Feb > 07 > Recall - ABS Module Reprogramming > Page 4910 The existing special tools may be required to perform this repair. NOTE: The StarSCAN and the Star Mobile scan tools must be at version 7.03 or higher before this procedure can be performed. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is shown. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > F50 > Feb > 07 > Recall - ABS Module Reprogramming > Page 4911 The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure NOTE: Reprogramming of the ABS Control Module can be performed using the StarSCAN scan tool or the StarMOBILE scan tool. A. Reprogram the ABS Control Module Using StarSCAN NOTE: The StarSCAN tool must be at version 7.03 or higher before this procedure can be performed. The software release level is visible in the blue header at the top of the StarSCAN screen. 1. Open the hood and install a battery charger. Verify that the charging rate provides approximately 13.5 volts. 2. Use the following procedure to determine the ABS Control Module software part number: a. Connect the StarSCAN to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. b. Power ON the StarSCAN. c. From the StarSCAN Home Screen, select "ECU View". d. From the StarSCAN ECU View Screen, select "ABS" from the list of modules. e. Select "More Options" and then select "ECU Flash". f. Record the part number displayed at the top of the "Flash ABS" screen for later reference. 3. Connect the CH9410 ethernet cable to the StarSCAN and the dealer's network drop. 4. Select "Browse for New File" and follow the on screen instructions. 5. Highlight the calibration and then select "Download to Scantool". 6. Select "Close" after the download is complete, disconnect the ethernet cable from the scan tool and then select "Back". 7. Highlight the listed calibration. 8. Select "Update Controller" and follow the screen instructions. 9. When the ABS control module update is complete, select "OK". 10. Verify the part number (resident flash file) at the top of the screen has updated to the new part number. 11. After completing the ABS control module reprogramming, clear all Diagnostic Trouble Codes (DTC's) using the following procedure: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > F50 > Feb > 07 > Recall - ABS Module Reprogramming > Page 4912 a. Return to the "Main Menu" (Home Page). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's" and follow the screen prompts. 12. Disconnect and remove the StarSCAN and battery charger from the vehicle. B. Reprogram the ABS Control Module Using StarMOBILE NOTE: The StarMOBILE scan tool must be at version 7.03 or higher before this procedure can be performed. 1. Open the hood and install a battery charger. Verify that the charging rate provides approximately 13.5 volts. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. Connect the CH9410 ethernet cable to the StarMOBILE and the dealer's network drop. 5. From the desktop, launch the "StarMOBILE Desktop Client" software. 6. From the main menu on the StarMOBILE, select "System Status". 7. Establish a connection with the StarMOBILE scan tool. 8. Select "Flash Download". 9. Select "Next" and then enter your ID and password. 10. Enter the vehicle information (manually or use the automatic function). 11. Highlight the required flash file and select "Download to Client". 12. Select "BACK" then select "ECU View". 13. Select "ABS Antilock Brakes". 14. Select "More Options". 15. Select "ECU Flash". 16. Select "Manage Files". 17. Highlight downloaded flash file. 18. Select "Copy to SM Devise" and then follow the screen prompts. 19. Disconnect the ethernet cable from the StarMOBILE scan tool. 20. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 21. From the "System Status" screen press the "Exit" button. 22. From the "Main Menu" select "Enter Standalone Diagnostic Mode". 23. Select "ECU View" and press the select button. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > F50 > Feb > 07 > Recall - ABS Module Reprogramming > Page 4913 24. Highlight "ABS" and press the select button. 25. Select "Flash ECU" and press the select button. 26. Verify the file number on the screen. If correct, press the select button and follow the screen prompts. 27. When the flash is complete, press the "OK" button. 28. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Return to the "Main Menu" (Home Page). b. From the "Home" screen, select "System View" and then select "All DTC's". c. Select the "Clear All Stored DTC's" and follow screen prompts. 29. Disconnect the StarMOBILE scan tool and battery charger from the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > F50 > Feb > 07 > Recall - ABS Module Reprogramming > Page 4914 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > NHTSA06V493000 > Dec > 06 > Recall 06V493000: ABS Control Module Software Update Electronic Brake Control Module: All Technical Service Bulletins Recall 06V493000: ABS Control Module Software Update MAKE/MODELS: MODEL/BUILD YEARS: Chrysler/300 2007 Chrysler/Sebring 2007 Dodge/Caliber 2007 Dodge/Charger 2007 Dodge/Magnum 2007 Dodge/Nitro 2007 Jeep/Commander 2007 Jeep/Compass 2007 Jeep/Grand Cherokee 2007 Jeep/Liberty 2007 Jeep/Wrangler 2007 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 06V493000 MFG'S REPORT DATE: December 22, 2006 COMPONENT: Service Brakes, Hydraulic: Antilock: Control Unit/Module POTENTIAL NUMBER OF UNITS AFFECTED: 62369 SUMMARY: On certain vehicles, the Antilock Brake System (ABS) control module software may cause the rear brakes to lock up during certain braking conditions. CONSEQUENCE: This could result in a loss of vehicle control and cause a crash without warning. REMEDY: Dealers will reprogram the ABS electronic control unit. The recall is expected to begin during February 2007. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. F50. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 4919 Electronic Brake Control Module: Locations Component ID: 146 Component : MODULE-ANTI-LOCK BRAKES Connector: Name : MODULE-ANTI-LOCK BRAKES Color : BLACK # of pins : 47 Gender : FEMALE Pin Description Circuit 1 FUSED B(+) (PUMP) A921 12RD/DB 2-3-4-5-6-- 7-8 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 9-10 - 11 - 12 CAN C BUS (+) D65 20WT/BK 13 CAN C BUS (-) D64 20WT/LB 14 - 15 - 16 GROUND Z909 12BK/WT 17 - 18 DYNAMICS SENSOR HIGH DATA LINK D465 20WT/DB 19 DYNAMICS SENSOR LOW DATA LINK D464 20WT/YL 20 - 21 - 22 DYNAMICS SENSOR SUPPLY G4 18VT/LB 23 - 24 - 25 - 26 - 27 - 28 - 29 DYNAMICS SENSOR GROUND G94 18VT/DB 30 - 31 - 32 FUSED B(+) (VALVE) A922 14RD/BK 33 RIGHT FRONT WHEEL SPEED SENSOR SIGNAL B6 20WT/DB 34 RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY B7 20WT Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 4920 35 - 36 LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY B4 20LG 37 LEFT REAR WHEEL SPEED SENSOR SIGNAL B3 20LG/DB 38 - 39 - 40 - 41 - 42 RIGHT REAR WHEEL SPEED SENSOR SIGNAL B1 20YL/DB 43 RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY B2 20YL 44 - 45 LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY B9 20DG/LG 46 LEFT FRONT WHEEL SPEED SENSOR SIGNAL B8 20DG/TN 47 GROUND Z909 12BK/WT Component Location - 5 Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 4921 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 4922 Electronic Brake Control Module: Diagrams Component ID: 146 Component : MODULE-ANTI-LOCK BRAKES Connector: Name : MODULE-ANTI-LOCK BRAKES Color : BLACK # of pins : 47 Gender : FEMALE Pin Description Circuit 1 FUSED B(+) (PUMP) A921 12RD/DB 2-3-4-5-6-- 7-8 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 9-10 - 11 - 12 CAN C BUS (+) D65 20WT/BK 13 CAN C BUS (-) D64 20WT/LB 14 - 15 - 16 GROUND Z909 12BK/WT 17 - 18 DYNAMICS SENSOR HIGH DATA LINK D465 20WT/DB 19 DYNAMICS SENSOR LOW DATA LINK D464 20WT/YL 20 - 21 - 22 DYNAMICS SENSOR SUPPLY G4 18VT/LB 23 - 24 - 25 - 26 - 27 - 28 - 29 DYNAMICS SENSOR GROUND G94 18VT/DB 30 - 31 - 32 FUSED B(+) (VALVE) A922 14RD/BK 33 RIGHT FRONT WHEEL SPEED SENSOR SIGNAL B6 20WT/DB 34 RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY B7 20WT Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 4923 35 - 36 LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY B4 20LG 37 LEFT REAR WHEEL SPEED SENSOR SIGNAL B3 20LG/DB 38 - 39 - 40 - 41 - 42 RIGHT REAR WHEEL SPEED SENSOR SIGNAL B1 20YL/DB 43 RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY B2 20YL 44 - 45 LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY B9 20DG/LG 46 LEFT FRONT WHEEL SPEED SENSOR SIGNAL B8 20DG/TN 47 GROUND Z909 12BK/WT Component Location - 5 Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 4924 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Description and Operation > Description Electronic Brake Control Module: Description and Operation Description DESCRIPTION The Antilock Brake Module (ABM) is a microprocessor-based device which monitors the antilock brake system (ABS) during normal braking and controls it when the vehicle is in an ABS stop or when in a traction control or Electronic Stability Program (ESP) situation. The ABM utilizes a 47-way electrical connector on the vehicle wiring harness. The power source for the ABM is through the ignition switch in the RUN or ON position. The ABM (1) is mounted to the HCU (2) as part of the Integrated Control Unit (ICU). The ICU is located in the engine compartment on the inboard side of the right body frame rail behind the strut tower. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Description and Operation > Description > Page 4927 Electronic Brake Control Module: Description and Operation Operation OPERATION The primary functions of the Antilock Brake Module (ABM) are to: - Monitor the Antilock Brake System (ABS) and Electronic Stability Program (ESP) for proper operation. - Detect wheel locking or wheel slipping tendencies by monitoring the speed of all four wheels of the vehicle. - Control fluid modulation to the wheel brakes while the system is in ABS or traction control mode. - Modulates fluid pressure to the wheel brakes to control vehicle yaw rate in ESP mode. - Store diagnostic information. - Provide communication to the scan tool while in diagnostic mode. - Illuminate the amber ABS indicator in the instrument cluster. - Illuminate the yellow ESP/BAS indicator in the instrument cluster (if equipped). The ABM constantly monitors the ABS and ESP (if equipped) for proper operation. If the ABM detects a fault, it will turn on the amber ABS and yellow ESP/BAS indicators and disable the ABS or ESP if so equipped. The normal base braking system will remain operational at that time. The ABM continuously monitors the speed of each wheel through the signals generated by the wheel speed sensors to determine if any wheel is beginning to lock. When a wheel locking tendency is detected, the ABM commands the ABM solenoid coils to actuate. The coils then open and close the valves in the HCU that modulate brake fluid pressure in some or all of the hydraulic circuits. The ABM continues to control pressure in individual hydraulic circuits until a locking tendency is no longer present. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Removal Electronic Brake Control Module: Service and Repair Removal REMOVAL Due to packaging and limited space it is necessary to remove and disassemble the Integrated Control Unit (ICU) to service the Antilock Brake Module (ABM) on this vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Removal > Page 4930 Electronic Brake Control Module: Service and Repair Installation INSTALLATION Due to packaging and limited space it is necessary to install the Antilock Brake Module (ABM) on the Hydraulic Control Unit (HCU), then install the Integrated Control Unit (ICU) on the vehicle as an assembly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > Hydraulic Control Unit (HCU) Hydraulic Control Assembly - Antilock Brakes: Description and Operation Hydraulic Control Unit (HCU) DESCRIPTION The Hydraulic Control Unit (HCU) is mounted to the Antilock Brake Module (ABM) as part of the Integrated Control Unit (ICU). The HCU controls the flow of brake fluid to the brakes using a series of valves and accumulators. A pump/motor is mounted on the HCU to supply build pressure to the brakes during an ABS stop. VALVES AND SOLENOIDS The valve block contains four inlet valves and four outlet solenoid valves. The inlet valves are spring-loaded in the open position and the outlet valves are spring-loaded in the closed position during normal braking. The fluid is allowed to flow from the master cylinder to the wheel brakes. During an ABS stop, these valves cycle to maintain the proper slip ratio for each wheel. The inlet valve closes preventing further pressure increase and the outlet valve opens to provide a path from the wheel brake to the HCU accumulators and pump/motor. This releases (decays) pressure from the wheel brake, thus releasing the wheel from excessive slippage. Once the wheel is no longer slipping, the outlet valve is closed and the inlet valve is opened to reapply (build) pressure. If the ABS includes the traction control feature, there are four other valves in the HCU. Two Traction Control (TC) valves, mounted in the HCU valve block, are normally in the open position and close only when the traction control is applied. There are also two shuttle valves which control pressure return to the master cylinder under ABS and traction control conditions. These TC valves are used to isolate the rear (non-driving) wheels of the vehicle from the hydraulic pressure that the HCU pump/motor is sending to the front (driving) wheels when traction control is being applied. The rear brakes need to be isolated from the master cylinder when traction control is being applied so the rear wheels do not drag. BRAKE FLUID ACCUMULATORS There are two fluid accumulators in the HCU: one for the primary hydraulic circuit, and one for the secondary hydraulic circuit. Each hydraulic circuit uses a 3 cc accumulator. The fluid accumulators temporarily store brake fluid that is removed from the wheel brakes during an ABS cycle. This stored fluid is used by the pump/motor to provide build pressure for the brake hydraulic system. When the antilock stop is complete, the accumulators are drained by the pump/motor. There are two noise dampening chambers in the HCU on this vehicle equipped with traction control. PUMP/MOTOR There are two pump assemblies in the HCU: one for the primary hydraulic circuit, and one for the secondary hydraulic circuit. Both pumps are driven by a common electric motor. This DC-type motor is integral to the HCU and is controlled by the ABM. The pump/motor provides the extra amount of brake fluid needed during antilock braking. Brake fluid is released to the accumulators when the outlet valve is opened during an antilock stop. The pump mechanism consists of two opposing pistons operated by an eccentric camshaft. In operation, these pistons are used to purge fluid from the accumulators back into the master cylinder circuits. When the antilock stop is complete, the pump/motor drains the accumulators. The pump motor is also used to build pressure when the system goes into Electronic Stability Program (ESP(R)) and traction control mode. The ABM may turn on the pump/motor when an antilock stop is detected. The pump/motor continues to run during the antilock stop and is turned off after the stop is complete. Under some conditions, the pump/motor runs to drain the accumulators during the next drive-off. The pump/motor is not a serviceable item; if it requires replacement, the HCU must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > Hydraulic Control Unit (HCU) > Page 4935 Hydraulic Control Assembly - Antilock Brakes: Description and Operation Integrated Control Unit (ICU) Description DESCRIPTION The Hydraulic Control Unit (HCU) (2) and the Antilock Brake Module (ABM) (1) used with this antilock brake system are combined (integrated) into one unit, which is called the Integrated Control Unit (ICU). The ICU (1) is located in the engine compartment, mounted to the right side body frame rail near the strut tower. Two different ICU's are used on this vehicle depending on whether or not the vehicle is equipped with traction control and Electronic Stability Program (ESP(R)). The HCU on a vehicle equipped with traction control or ESP(R) has a valve block that is approximately one inch longer than a HCU on a vehicle that is equipped with ABS only. The ABS-only ICU consists of the following components: the ABM, eight (build/decay) solenoid valves (four inlet valves and four outlet valves), valve Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > Hydraulic Control Unit (HCU) > Page 4936 block, fluid accumulators, a pump, and an electric motor. The ABS with ESP(R) and All-Speed Traction Control ICU consists of the following components: the ABM, 12 (build/decay) solenoid valves, two traction control solenoid valves, two hydraulic shuttle valves, valve block, fluid accumulators, a pump, and an electric pump/motor. The replaceable components of the ICU are the HCU and the ABM. No attempt should be made to service any components of the HCU or ABM. For additional information on the ABM, Refer to ANTILOCK BRAKE MODULE - DESCRIPTION). For additional information on the HCU, Refer to BRAKES ABS/HYDRAULIC/MECHANICAL/HCU (HYDRAULIC CONTROL UNIT) - DESCRIPTION). Operation OPERATION For information of the ICU, refer to these individual components of the ICU: - ANTILOCK BRAKE MODULE (ABM) Refer to ANTILOCK BRAKE MODULE DESCRIPTION - HYDRAULIC CONTROL UNIT (HCU) Refer to HYDRAULIC CONTROL UNIT - DESCRIPTION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Replacement Hydraulic Control Assembly - Antilock Brakes: Removal and Replacement Removal REMOVAL To remove the HCU, the ICU must be removed and disassembled. Installation INSTALLATION To install the HCU, assemble and install the ICU. Removal INTEGRATED CONTROL UNIT - GAS ENGINE NOTE: Refer to Warnings and Cautions. 1. Disconnect and isolate battery negative cable from battery post. 2. Using a brake pedal holding tool as shown, depress the brake pedal past its first 25 mm (1 inch) of travel and hold it in this position. This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir while the lines are disconnected. 3. Remove the engine appearance cover. 4. Loosen lower and upper mounting nuts, then remove the exhaust heat shield from the dash panel. 5. Pull the brake tube bundle routing clips (with tubes) loose from studs on the dash panel. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 4939 6. Remove the primary (4) and secondary (1) brake tubes (from master cylinder) at the hydraulic control unit (7). 7. Remove the remaining brake tubes (2, 3, 5, 6) at the hydraulic control unit (7). 8. Remove the screw (1) fastening the power steering pressure hose routing clamp (2) to the exhaust manifold. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 4940 NOTE: Use this figure in the following step to release the ABM harness connector cover. It shows the location of the release tabs. 9. Disconnect the ABM harness connector from the Antilock Brake Module (ABM). To do so: a. Depress the tabs on each side of the connector cover, then b. Pull outward and upward on the lower half of the cover until it locks into position pointing straight outward (2). The connector can then be pulled straight outward off the ABM (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 4941 10. Loosen, but do not remove, the two mounting screws (2) attaching the ICU (1) mounting bracket to the body. 11. Lift the ICU and mounting bracket (1) off the mounting screws (2). 12. Move the brake tubes around as necessary without bending them and remove the ICU with bracket through the opening between the A/C lines and the exhaust manifold. 13. To separate the ABM from the HCU, Refer to BRAKES/HYDRAULIC/MECHANICAL/ICU (INTEGRATED CONTROL UNIT) DISASSEMBLY. Installation INTEGRATED CONTROL UNIT - GAS ENGINE 1. Install the ICU with bracket (1) through the opening between the A/C lines and the exhaust manifold using the opposite of how it was removed. 2. Place the mounting bracket for the ICU (1) over the mounting screws (2) and hang the assembly in place. Tighten the two mounting screws (2) to 23 Nm (17 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 4942 CAUTION: Before installing the ABM harness connector on the ABM, be sure the seal is properly installed in the connector. 3. Insert the ABM wiring harness connector (2) into the socket of the ABM (1) and close the cover, locking the connector in place. 4. Install the four chassis brake tubes (2, 3, 5, 6) brake tubes at the ICU hydraulic control unit (7). Tighten the tube nuts to 17 Nm (150 in. lbs.). 5. Install the primary (4) and secondary (1) brake tubes at the ICU hydraulic control unit (7). Tighten the tube nuts to 17 Nm (150 in. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 4943 6. Position the power steering pressure hose routing clamp (2) on the exhaust manifold and install the mounting screw (1). Tighten the mounting screw to 9 Nm (80 in. lbs.). 7. Push the brake tube bundle routing clips (with tubes) onto the studs on the dash panel. 8. Install the heat shield on the dash panel and tighten the lower and upper mounting nuts. 9. Remove the brake pedal holding tool. 10. Install the engine appearance cover. 11. Connect the battery negative cable to the battery post. It is important that this be performed properly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 4944 12. Hook up the scan tool to initialize the ABM and perform the following: a. Clear any faults. b. Fill the master cylinder to the proper fill level and bleed the base and ABS hydraulic systems. c. Check for leaks. d. Perform the ABS Verification Test and road test the vehicle. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 4945 Hydraulic Control Assembly - Antilock Brakes: Overhaul Disassembly DISASSEMBLY 1. If the mounting bracket (3) needs to be removed from the ICU, remove the single mounting bolt (2), then slide the ICU's mounting pins out of the grommets in the bracket and remove the bracket. 2. Remove the mounting pins from the ICU. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 4946 3. If not equipped with ESP(R) or traction control, remove the three screws (1) attaching the ABM (2) to the HCU. 4. If equipped with ESP(R) or traction control, remove the four screws (1) attaching the ABM (2) to the HCU. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 4947 5. Separate the ABM (1) from the HCU (2). Assembly ASSEMBLY 1. Clean any debris off the mating surfaces of the HCU and ABM. CAUTION: When installing new O-rings or solenoid valve stem seals, do not use any type of lubricant. 2. If the seals (1) on the solenoid valve stems (2) are not new, replace them all. Each of the solenoid valve stem seals must be new to keep out moisture and debris; do not reuse solenoid valve stem seals. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 4948 3. Replace the pump/motor connector O-ring (1) if it is not new. Be sure the O-ring is properly seated in the mounting groove (2). 4. Align components and install the ABM (1) on the HCU (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 4949 5. If not equipped with ESP(R) or traction control, install the three screws (1) attaching the ABM (2) to the HCU. Tighten the mounting screws to 2 Nm (17 in. lbs.). 6. If equipped with ESP(R) or traction control, install the four screws (1) attaching the ABM (2) to the HCU. Tighten the mounting screws to 2 Nm (17 in. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 4950 7. If necessary, install the mounting pins (1) in the ICU (2) and tighten to 11 Nm (97 in. lbs.). 8. If the mounting bracket (3) needs to be installed on the ICU (1), install the mounting pins in the ICU as necessary and tighten to 11 Nm (97 in. lbs.). Insert the mounting pins into the grommets mounted in the bracket, then install the single mounting bolt (2). Tighten the mounting bolt to 11 Nm (97 in. lbs.). 9. Install the ICU in the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Locations Lateral Accelerometer: Locations Component ID: 288 Component : SENSOR-DYNAMICS Connector: Name : SENSOR-DYNAMICS Color : BLACK # of pins : 6 Qualifier : (ESP) Pin Description Circuit 1 DYNAMICS SENSOR LOW DATA LINK D464 20WT/YL 2 DYNAMICS SENSOR HIGH DATA LINK D465 20WT/DB 3 DYNAMICS SENSOR SUPPLY G4 18VT/LB 4-5 DYNAMICS SENSOR GROUND G94 18VT/DB 6-- Component Location - 45 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Locations > Page 4954 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Locations > Page 4955 Lateral Accelerometer: Diagrams Component ID: 288 Component : SENSOR-DYNAMICS Connector: Name : SENSOR-DYNAMICS Color : BLACK # of pins : 6 Qualifier : (ESP) Pin Description Circuit 1 DYNAMICS SENSOR LOW DATA LINK D464 20WT/YL 2 DYNAMICS SENSOR HIGH DATA LINK D465 20WT/DB 3 DYNAMICS SENSOR SUPPLY G4 18VT/LB 4-5 DYNAMICS SENSOR GROUND G94 18VT/DB 6-- Component Location - 45 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Locations > Page 4956 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Locations > Page 4957 Lateral Accelerometer: Description and Operation DESCRIPTION The Yaw Rate and Lateral Acceleration Sensors are housed into one unit known as the Dynamics Sensor (1). The sensor is used to measure side-to-side (Lateral) motion and vehicle rotational sensing (how fast the vehicle is turning - Yaw). Yaw and Lateral Acceleration Sensors cannot be serviced separately. The entire Dynamics Sensor must be replaced when necessary. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Service and Repair > Removal Lateral Accelerometer: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable from the battery post. 2. Remove the shifter housing center console. 3. Disconnect the wiring harness connector (3) at the dynamics sensor (1). 4. Remove the nuts (2) mounting the dynamics sensor to the floor pan tunnel (4). 5. Remove the dynamics sensor (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Service and Repair > Removal > Page 4960 Lateral Accelerometer: Service and Repair Installation INSTALLATION 1. Install the dynamics sensor (1) over the studs mounted to the floor pan tunnel (4). 2. Install the two mounting nuts (2). Tighten the nuts to 9 Nm (80 in. lbs.). 3. Connect the wiring harness connector (3) to the dynamics sensor (1). 4. Install the shifter housing center console. 5. Connect the battery negative cable to the battery post. It is important that this be performed properly. 6. Perform the Verification Test and clear any faults. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Steering Angle Sensor, Traction Control > Component Information > Locations Steering Angle Sensor: Locations Component ID: 316 Component : SENSOR-STEERING ANGLE Connector: Name : SENSOR-STEERING ANGLE Color : WHITE # of pins : 4 Pin Description Circuit 1 CAN C BUS (+) D265 20DB/LB 2 CAN C BUS (-) D264 20DB/WT 3 GROUND Z937 20BK/YL 4 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY Component Location - 28 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Steering Angle Sensor, Traction Control > Component Information > Locations > Page 4964 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Steering Angle Sensor, Traction Control > Component Information > Locations > Page 4965 Steering Angle Sensor: Diagrams Component ID: 316 Component : SENSOR-STEERING ANGLE Connector: Name : SENSOR-STEERING ANGLE Color : WHITE # of pins : 4 Pin Description Circuit 1 CAN C BUS (+) D265 20DB/LB 2 CAN C BUS (-) D264 20DB/WT 3 GROUND Z937 20BK/YL 4 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY Component Location - 28 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Steering Angle Sensor, Traction Control > Component Information > Locations > Page 4966 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Steering Angle Sensor, Traction Control > Component Information > Locations > Page 4967 Steering Angle Sensor: Description and Operation DESCRIPTION The steering angle sensor is an integral part of the clockspring (3) mounted on the steering column. Refer to CLOCKSPRING - DESCRIPTION) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Description and Operation Traction Control Switch: Description and Operation DESCRIPTION The ESP Off Switch is part of the accessory switch bank module located in the center bezel on the instrument panel above the transmission gear shifter. The ESP Off switch turns the Electronic Stability Program off whenever the switch is depressed. Depressing the switch a second time turns the ESP(R) back on. The switch resets itself each time the ignition is cycled. When the ESP Off switch is depressed and released, turning ESP(R) off, it does not completely turn the system off. The ESP(R) system reduces torque management to a lesser amount, but ESP(R) function can still occur if the system perceives the need. The ESP Off switch is serviced as part of the accessory switch bank. There are different accessory switch banks available based on the option content of the vehicle. Ensure the accessory switch bank being installed matches the vehicle options. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Service and Repair > Removal Traction Control Switch: Service and Repair Removal REMOVAL NOTE: The ESP Off switch is integral to the accessory switch bank and cannot be serviced separately. 1. Disconnect and isolate the negative battery cable. 2. Remove the center bezel from the instrument panel and place it on a work bench. 3. Remove the screws that secure the accessory switch bank to the back of the center bezel and remove the accessory switch bank. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Service and Repair > Removal > Page 4973 Traction Control Switch: Service and Repair Installation INSTALLATION NOTE: The ESP Off switch is serviced as part of the accessory switch bank. NOTE: There are different instrument panel accessory switch banks available based on the option content of the vehicle. Ensure the accessory switch bank being installed matches the vehicle options. 1. Position the accessory switch bank onto the back of the instrument panel center bezel. 2. Install the screws that secure the accessory switch bank to the center bezel. Tighten the screws to 2 Nm (17 in. lbs.). 3. Install the center bezel onto the instrument panel. 4. Reconnect the negative battery cable. 5. Perform the ABS Verification Test and make sure the ESP Off switch operates properly. 6. Verify proper operation of all components controlled by the switch bank. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front Wheel Speed Sensor: Locations Sensor-Wheel Speed-ABS-Left Front Component ID: 319 Component : SENSOR-WHEEL SPEED-ABS-LEFT FRONT Connector: Name : SENSOR-WHEEL SPEED-ABS-LEFT FRONT Color : BLACK # of pins : 2 Pin Description Circuit 1 LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY B9 20DG/LG 2 LEFT FRONT WHEEL SPEED SENSOR SIGNAL B8 20DG/TN Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 4978 Connector: Name : SENSOR-WHEEL SPEED-ABS-LEFT FRONT Color : # of pins : 2 Qualifier : (SENSOR SIDE) Pin Description Circuit 1 LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY DG/LG 2 LEFT FRONT WHEEL SPEED SENSOR SIGNAL DG/TN Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 4979 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 4980 Wheel Speed Sensor: Locations Sensor-Wheel Speed-ABS-Left Rear Component ID: 320 Component : SENSOR-WHEEL SPEED-ABS-LEFT REAR Connector: Name : SENSOR-WHEEL SPEED-ABS-LEFT REAR Color : BLACK # of pins : 2 Pin Description Circuit 1 LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY B4 20LG/BK 2 LEFT REAR WHEEL SPEED SENSOR SIGNAL B3 20LG/DB Component Location - 60 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 4981 Connector: Name : SENSOR-WHEEL SPEED-ABS-LEFT REAR Color : # of pins : 2 Qualifier : (SENSOR SIDE) Pin Description Circuit 1 LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY LG 2 LEFT REAR WHEEL SPEED SENSOR SIGNAL LG/DB Component Location - 60 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 4982 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 4983 Wheel Speed Sensor: Locations Sensor-Wheel Speed-ABS-Right Front Component ID: 321 Component : SENSOR-WHEEL SPEED-ABS-RIGHT FRONT Connector: Name : SENSOR-WHEEL SPEED-ABS-RIGHT FRONT Color : BLACK # of pins : 2 Pin Description Circuit 1 RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY B7 20WT 2 RIGHT FRONT WHEEL SPEED SENSOR SIGNAL B6 20WT/DB Component Location - 5 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 4984 Component Location - 6 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 4985 Connector: Name : SENSOR-WHEEL SPEED-ABS-RIGHT FRONT Color : # of pins : 2 Qualifier : (SENSOR SIDE) Pin Description Circuit 1 RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY WT 2 RIGHT FRONT WHEEL SPEED SENSOR SIGNAL WT/DB Component Location - 5 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 4986 Component Location - 6 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 4987 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 4988 Wheel Speed Sensor: Locations Sensor-Wheel Speed-ABS-Right Rear Component ID: 322 Component : SENSOR-WHEEL SPEED-ABS-RIGHT REAR Connector: Name : SENSOR-WHEEL SPEED-ABS-RIGHT REAR Color : BLACK # of pins : 2 Pin Description Circuit 1 RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY B2 20DG/LB 2 RIGHT REAR WHEEL SPEED SENSOR SIGNAL B1 20DG/OR 2 RIGHT REAR WHEEL SPEED SENSOR SIGNAL B1 20YL/DB Component Location - 63 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 4989 Connector: Name : SENSOR-WHEEL SPEED-ABS-RIGHT REAR Color : # of pins : 2 Qualifier : (SENSOR SIDE) Pin Description Circuit 1 RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY DG/LB 2 RIGHT REAR WHEEL SPEED SENSOR SIGNAL DG/OR Component Location - 63 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 4990 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front Wheel Speed Sensor: Diagrams Sensor-Wheel Speed-ABS-Left Front Component ID: 319 Component : SENSOR-WHEEL SPEED-ABS-LEFT FRONT Connector: Name : SENSOR-WHEEL SPEED-ABS-LEFT FRONT Color : BLACK # of pins : 2 Pin Description Circuit 1 LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY B9 20DG/LG 2 LEFT FRONT WHEEL SPEED SENSOR SIGNAL B8 20DG/TN Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 4993 Connector: Name : SENSOR-WHEEL SPEED-ABS-LEFT FRONT Color : # of pins : 2 Qualifier : (SENSOR SIDE) Pin Description Circuit 1 LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY DG/LG 2 LEFT FRONT WHEEL SPEED SENSOR SIGNAL DG/TN Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 4994 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 4995 Wheel Speed Sensor: Diagrams Sensor-Wheel Speed-ABS-Left Rear Component ID: 320 Component : SENSOR-WHEEL SPEED-ABS-LEFT REAR Connector: Name : SENSOR-WHEEL SPEED-ABS-LEFT REAR Color : BLACK # of pins : 2 Pin Description Circuit 1 LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY B4 20LG/BK 2 LEFT REAR WHEEL SPEED SENSOR SIGNAL B3 20LG/DB Component Location - 60 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 4996 Connector: Name : SENSOR-WHEEL SPEED-ABS-LEFT REAR Color : # of pins : 2 Qualifier : (SENSOR SIDE) Pin Description Circuit 1 LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY LG 2 LEFT REAR WHEEL SPEED SENSOR SIGNAL LG/DB Component Location - 60 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 4997 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 4998 Wheel Speed Sensor: Diagrams Sensor-Wheel Speed-ABS-Right Front Component ID: 321 Component : SENSOR-WHEEL SPEED-ABS-RIGHT FRONT Connector: Name : SENSOR-WHEEL SPEED-ABS-RIGHT FRONT Color : BLACK # of pins : 2 Pin Description Circuit 1 RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY B7 20WT 2 RIGHT FRONT WHEEL SPEED SENSOR SIGNAL B6 20WT/DB Component Location - 5 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 4999 Component Location - 6 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 5000 Connector: Name : SENSOR-WHEEL SPEED-ABS-RIGHT FRONT Color : # of pins : 2 Qualifier : (SENSOR SIDE) Pin Description Circuit 1 RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY WT 2 RIGHT FRONT WHEEL SPEED SENSOR SIGNAL WT/DB Component Location - 5 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 5001 Component Location - 6 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 5002 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 5003 Wheel Speed Sensor: Diagrams Sensor-Wheel Speed-ABS-Right Rear Component ID: 322 Component : SENSOR-WHEEL SPEED-ABS-RIGHT REAR Connector: Name : SENSOR-WHEEL SPEED-ABS-RIGHT REAR Color : BLACK # of pins : 2 Pin Description Circuit 1 RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY B2 20DG/LB 2 RIGHT REAR WHEEL SPEED SENSOR SIGNAL B1 20DG/OR 2 RIGHT REAR WHEEL SPEED SENSOR SIGNAL B1 20YL/DB Component Location - 63 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 5004 Connector: Name : SENSOR-WHEEL SPEED-ABS-RIGHT REAR Color : # of pins : 2 Qualifier : (SENSOR SIDE) Pin Description Circuit 1 RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY DG/LB 2 RIGHT REAR WHEEL SPEED SENSOR SIGNAL DG/OR Component Location - 63 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 5005 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Front Wheel Speed Wheel Speed Sensor: Description and Operation Front Wheel Speed Description DESCRIPTION The antilock brake system uses two-wire wheel speed sensors, known as active wheel speed sensors. The sensors use an electronic principle known as magnetoresistive to help increase performance and durability. The sensors convert wheel speed into a small digital signal. A Wheel Speed Sensor (WSS) is used at each wheel. A magnetic pole encoder serves as the trigger mechanism for each sensor. At each wheel of the vehicle there is one wheel speed sensor and one encoder. A front wheel speed sensor (3) is attached to a mounting boss on each front knuckle (4). The encoder is an integral part of the hub and bearing. WSS air gaps are not adjustable. Operation OPERATION The ABM sends 12 volts to power an Integrated Circuit (IC) in the sensor. The IC supplies a constant 7 mA power supply to the ABM. The relationship of the magnetic pole encoder to the permanent magnet in the sensor, signals the IC to enable a second 7 mA power supply. The output of the sensor, sent to the ABM, is a DC voltage signal with changing voltage and current levels. The ground for the IC and the current sense circuit is provided by the ABM. When a pole is properly aligned with the sensor, the voltage signal is approximately 0.8 volts and a constant 7 mA current is sent to the ABM. As the magnetic pole encoder rotates, the encoder shifts the magnetic field and the IC enables a second 7 mA current source. The ABM senses a voltage signal of approximately 1.6 volts and 14 mA. The ABM measures the amperage of the digital signal for each wheel. The resulting signal is interpreted by the ABM as the wheel speed. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Front Wheel Speed > Page 5008 Wheel Speed Sensor: Description and Operation Rear Wheel Speed Description DESCRIPTION The antilock brake system uses two-wire wheel speed sensors, known as active wheel speed sensors. The sensors use an electronic principle known as magnetoresistive to help increase performance and durability. The sensors convert wheel speed into a small digital signal. A Wheel Speed Sensor (WSS) is used at each wheel. A magnetic pole encoder serves as the trigger mechanism for each sensor. At each wheel of the vehicle there is one wheel speed sensor and one encoder. On all-wheel-drive vehicles, the rear wheel speed sensor head (1) is secured to the rear hub and bearing (2) by a spring-loaded clip on the rear of the assembly. The encoder is integral to the hub and bearing assembly. The encoder is serviced as part of the rear hub and bearing. On front-wheel-drive vehicles, the rear wheel speed sensor head (3) is mounted to the rear of the hub and bearing by a screw. The encoder is integral to the hub and bearing assembly. The encoder is are serviced as part of the rear hub and bearing. The WSS air gaps are not adjustable. Operation OPERATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Front Wheel Speed > Page 5009 The ABM sends 12 volts to power an Integrated Circuit (IC) in the sensor. The IC supplies a constant 7 mA power supply to the ABM. The relationship of the magnetic pole encoder to the permanent magnet in the sensor, signals the IC to enable a second 7 mA power supply. The output of the sensor, sent to the ABM, is a DC voltage signal with changing voltage and current levels. The ground for the IC and the current sense circuit is provided by the ABM. When a pole is properly aligned with the sensor, the voltage signal is approximately 0.8 volts and a constant 7 mA current is sent to the ABM. As the magnetic pole encoder rotates, the encoder shifts the magnetic field and the IC enables a second 7 mA current source. The ABM senses a voltage signal of approximately 1.6 volts and 14 mA. The ABM measures the amperage of the digital signal for each wheel. The resulting signal is interpreted by the ABM as the wheel speed. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Wheel Speed Sensor: Service and Repair Front Wheel Speed Removal REMOVAL NOTE: Refer to Warnings and Cautions. 1. Open the hood. 2. Disconnect the wheel speed sensor cable connector (2) from the wiring harness connector (3) on top of the frame rail (1) to the inside of the strut tower. 3. Raise and support the vehicle. 4. Remove the grommet (1) from the hole in the body (7) and pull the wheel speed sensor cable out of the hole. 5. Remove the speed sensor cable routing clip (2) from the outside frame rail (6). 6. Remove the screw fastening the cable routing clamp (3) to the outside frame rail (6). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 5012 7. Remove the screw (1) securing the wheel speed sensor routing bracket (2) to the brake flex hose bracket (5). 8. Remove the mounting screw (2) fastening the wheel speed sensor head (3) to the knuckle (4). Pull the sensor head out of the knuckle. NOTE: In the following step, the routing clip can be easily removed without damaging it by rotating it (with entire sensor) counterclockwise. 9. Remove the routing clip (1) securing wheel speed sensor cable to the knuckle (4). Remove the sensor from the vehicle. Installation INSTALLATION CAUTION: Failure to install speed sensor cables properly may result in contact with moving parts or an over extension of cables causing an open circuit. Be sure that cables are installed, routed, and clipped properly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 5013 1. Install the wheel speed sensor head (3) into the knuckle (4). Install the mounting screw (2) and tighten it to 12 Nm (106 in. lbs.). 2. Install the routing clip (1) securing the wheel speed sensor cable to the knuckle (4). 3. Position the wheel speed sensor routing bracket (2) on the brake flex hose bracket (5) and install the mounting screw (1). Tighten the mounting screw to 18 Nm (13 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 5014 4. Position the wheel speed sensor cable routing clamp (4) on the outside frame rail (6) and install the mounting screw (3). Tighten the mounting screw to 18 Nm (13 ft. lbs.). 5. Install the speed sensor cable routing clip (2) on the outside frame rail (6). 6. Insert the wheel speed sensor cable through the hole in the body (7) and install the grommet (1) in the hole. 7. Lower the vehicle. 8. Connect the wheel speed sensor cable connector (2) to the wiring harness connector (3) on top of the frame rail (1). 9. Perform the Diagnostic Verification Test and clear any faults. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 5015 Wheel Speed Sensor: Service and Repair Rear Wheel Speed All-Wheel-Drive ALL-WHEEL-DRIVE CAUTION: Failure to install speed sensor cables properly may result in contact with moving parts or an over extension of cables causing an open circuit. Be sure that cables are installed, routed, and clipped properly. NOTE: When installing the sensor head to the spring-loaded retainer on the hub and bearing, make sure the head is held snug in the retainer. If there is any play, the clip is deformed and the hub and bearing must be replaced. The retainer is not serviced separately. 1. Clip the wheel speed sensor head (1) (flat side to bearing rear face) into the spring-loaded retainer on the rear of the hub and bearing (2). 2. Position the wheel speed sensor (3) on the trailing link (2) and install the screw (4) securing it in place. Tighten the mounting screw to 18 Nm (13 ft. lbs.). 3. Position the wheel speed sensor (3) and install the routing clip (1) fastening the sensor to the trailing link (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 5016 4. Position the wheel speed sensor cable routing clamp (3) on the rear suspension crossmember (4) and install the mounting screw (1). Tighten the mounting screw to 18 Nm (13 ft. lbs.). 5. Install the speed sensor cable routing clip (3) on the outside frame rail (4). NOTE: When inserting the wheel speed sensor cable through the hole in the body, route the cable toward the shock tower to make it easier to grasp the cable to connect it to the body wiring harness connector in a later step. 6. Insert the wheel speed sensor cable (5) through the hole in the body (1) and install the grommet (2) in the hole. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 5017 7. Install the tire and wheel assembly (1). Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 8. Lower the vehicle. 9. Through the opening in the bottom of the quarter trim panel, connect the wheel speed sensor cable connector (2) to the body wiring harness connector (3). 10. If equipped, install the satellite receiver (1) or amplifier (2) to rear floor pan. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 5018 11. Install the rear floor pan silencer (1). 12. Install the cargo floor cover. 13. Perform the Diagnostic Verification Test and clear any faults. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests Installation - FWD FRONT-WHEEL-DRIVE 1. Install the wheel speed sensor head (3) into the rear of the hub and bearing (2). 2. Install the wheel speed sensor head mounting screw (1). Tighten the screw to 10 Nm (89 in. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 5019 3. Position the wheel speed sensor (3) on the trailing link (2) and install the screw (4) securing it in place. Tighten the mounting screw to 18 Nm (13 ft. lbs.). 4. Position the wheel speed sensor (3) and install the routing clip (1) fastening the sensor to the trailing link (2). 5. Position the wheel speed sensor cable routing clamp (3) on the rear suspension crossmember (4) and install the mounting screw (1). Tighten the mounting screw to 18 Nm (13 ft. lbs.). 6. Install the speed sensor cable routing clip (3) on the outside frame rail (4). NOTE: When inserting the wheel speed sensor cable through the hole in the body, route the cable toward the shock tower to make it easier to grasp the cable to connect it to the body wiring harness connector in a later step. 7. Insert the wheel speed sensor cable (5) through the hole in the body (1) and install the grommet (2) in the hole. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 5020 8. Install the tire and wheel assembly (1). Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 9. Lower the vehicle. 10. Through the opening in the bottom of the quarter trim panel, connect the wheel speed sensor cable connector (2) at the body wiring harness connector (3). 11. If equipped, install the satellite receiver (1) or amplifier (2) to rear floor pan. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 5021 12. Install the rear floor pan silencer (1). 13. Install the cargo floor cover. 14. Perform the Diagnostic Verification Test and clear any faults. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests All-Wheel-Drive ALL-WHEEL-DRIVE NOTE: Refer to Warnings and Cautions. 1. Remove the cargo floor cover. 2. Remove the rear floor pan silencer (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 5022 3. If equipped, remove the nuts mounting the satellite receiver (1) or amplifier (2) to rear floor pan. Move the component aside to allow access to the wheel speed sensor wiring connector through the opening in bottom of the quarter trim panel. 4. Through the opening in the bottom of the quarter trim panel, disconnect the wheel speed sensor cable connector (2) at the body wiring harness connector (3). 5. Raise and support the vehicle. 6. Remove the wheel mounting nuts (3), then the rear tire and wheel assembly (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 5023 7. Remove the grommet (2) from the hole in the body (1) and pull the wheel speed sensor cable out through the hole. 8. Remove the speed sensor cable routing clip (3) from the outside frame rail (4). 9. Remove the screw (1) fastening the cable routing clamp (3) to the rear suspension crossmember (4). 10. Remove the speed sensor cable routing clip (1) from the trailing link (2). 11. Remove the screw (4) fastening the cable routing clamp to the trailing link. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 5024 12. Unclip the wheel speed sensor head (1) from the spring-loaded retainer on the rear of the hub and bearing (2). Remove the sensor from the vehicle. Removal - FWD FRONT-WHEEL-DRIVE NOTE: Refer to Warnings and Cautions. 1. Remove the cargo floor cover. 2. Remove the rear floor pan silencer (1). 3. If equipped, remove the nuts mounting the satellite receiver (1) or amplifier (2) to rear floor pan. Move the component aside to allow access to the wheel speed sensor wiring connector through the opening in bottom of the quarter trim panel. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 5025 4. Through the opening in the bottom of the quarter trim panel, disconnect the wheel speed sensor cable connector (2) at the body wiring harness connector (3). 5. Raise and support the vehicle. 6. Remove the wheel mounting nuts (3), then the rear tire and wheel assembly (1). 7. Remove the grommet (2) from the hole in the body (1) and pull the wheel speed sensor cable out through the hole. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 5026 8. Remove the speed sensor cable routing clip (3) from the outside frame rail (4). 9. Remove the screw (1) fastening the cable routing clamp (3) to the rear suspension crossmember (4). 10. Remove the speed sensor cable routing clip (1) from the trailing link (2). 11. Remove the screw (4) fastening the cable routing clamp to the trailing link. 12. Remove the screw (1) fastening the wheel speed sensor head (3) in the rear of the hub and bearing (2). Remove the sensor from the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Locations Yaw Rate Sensor: Locations Component ID: 288 Component : SENSOR-DYNAMICS Connector: Name : SENSOR-DYNAMICS Color : BLACK # of pins : 6 Qualifier : (ESP) Pin Description Circuit 1 DYNAMICS SENSOR LOW DATA LINK D464 20WT/YL 2 DYNAMICS SENSOR HIGH DATA LINK D465 20WT/DB 3 DYNAMICS SENSOR SUPPLY G4 18VT/LB 4-5 DYNAMICS SENSOR GROUND G94 18VT/DB 6-- Component Location - 45 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Locations > Page 5030 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Locations > Page 5031 Yaw Rate Sensor: Diagrams Component ID: 288 Component : SENSOR-DYNAMICS Connector: Name : SENSOR-DYNAMICS Color : BLACK # of pins : 6 Qualifier : (ESP) Pin Description Circuit 1 DYNAMICS SENSOR LOW DATA LINK D464 20WT/YL 2 DYNAMICS SENSOR HIGH DATA LINK D465 20WT/DB 3 DYNAMICS SENSOR SUPPLY G4 18VT/LB 4-5 DYNAMICS SENSOR GROUND G94 18VT/DB 6-- Component Location - 45 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Locations > Page 5032 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Locations > Page 5033 Yaw Rate Sensor: Description and Operation DESCRIPTION The Yaw Rate and Lateral Acceleration Sensors are housed into one unit known as the Dynamics Sensor (1). The sensor is used to measure side-to-side (Lateral) motion and vehicle rotational sensing (how fast the vehicle is turning - Yaw). Yaw and Lateral Acceleration Sensors cannot be serviced separately. The entire Dynamics Sensor must be replaced when necessary. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Service and Repair > Removal Yaw Rate Sensor: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable from the battery post. 2. Remove the shifter housing center console. 3. Disconnect the wiring harness connector (3) at the dynamics sensor (1). 4. Remove the nuts (2) mounting the dynamics sensor to the floor pan tunnel (4). 5. Remove the dynamics sensor (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Service and Repair > Removal > Page 5036 Yaw Rate Sensor: Service and Repair Installation INSTALLATION 1. Install the dynamics sensor (1) over the studs mounted to the floor pan tunnel (4). 2. Install the two mounting nuts (2). Tighten the nuts to 9 Nm (80 in. lbs.). 3. Connect the wiring harness connector (3) to the dynamics sensor (1). 4. Install the shifter housing center console. 5. Connect the battery negative cable to the battery post. It is important that this be performed properly. 6. Perform the Verification Test and clear any faults. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding Brake Bleeding: Service and Repair Master Cylinder Bleeding MASTER CYLINDER BLEEDING NOTE: On vehicles without ABS this procedure is designed to be performed with the proportioning valves installed in the master cylinder. 1. Clamp the master cylinder in a vise with soft-jaw caps. 2. Master Cylinder without ABS - Attach the special tools for bleeding the master cylinder in the following fashion: a. Thread Bleeder Tube Adapter (1), Special Tool 8822-1, into the primary outlet port of the master cylinder without a proportioning valve. Tighten Adapter to 17 Nm (150 in. lbs.). b. Thread Bleeder Tube Adapter (2), Special Tool 8822-2, into the secondary outlet port of the master cylinder without a proportioning valve. Tighten Adapter to 17 Nm (150 in. lbs.). c. Thread Bleeder Tube Adapter (4), Special Tool 8822-1, into the proportioning valve in the lower secondary outlet port of the master cylinder. Tighten Adapter to 17 Nm (150 in. lbs.). d. Thread Bleeder Tube Adapter (5), Special Tool 8822-2, into the proportioning valve in the lower primary outlet port of the master cylinder. Tighten Adapter to 17 Nm (150 in. lbs.). e. Thread a Bleeder Tube (6), Special Tool 8358-1, into each Adapter. Tighten tube nuts to 17 Nm (150 in. lbs.). f. Install Bleeder Tubes Adapter (3), Special Tool 9705, in place of the fill cap as shown. g. Flex and place the open ends of the Bleeder Tubes into open hose tips on Adapter 9705. Be sure Bleeder Tubes are inserted into Adapter 9705 far enough not to come loose during bleed procedure. 3. Master Cylinder with ABS - Attach the special tools for bleeding the master cylinder in the following fashion: a. Thread Bleeder Tube Adapters (3), Special Tool 8822-2, into the primary and secondary outlet ports of the master cylinder. Tighten Adapters to 17 Nm (150 in. lbs.). b. Thread a Bleeder Tube (2), Special Tool 8358-1, into each Adapter. Tighten tube nuts to 17 Nm (150 in. lbs.). c. Flex each Bleeder Tube and place the open ends into the neck of the master cylinder reservoir. Position the open ends of the tubes into the reservoir so their outlets are below the surface of the brake fluid in the reservoir when filled. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 5041 NOTE: Make sure the ends of the Bleeder Tubes stay below the surface of the brake fluid in the reservoir at all times during the bleeding procedure. 4. Fill the brake fluid reservoir with fresh Mopar(R) Brake Fluid DOT 3 Motor Vehicle, or equivalent. 5. Using an appropriately sized wooden dowel as a pushrod, slowly press the pistons inward discharging brake fluid through the Bleeder Tubes, then release the pressure, allowing the pistons to return to the released position. Repeat this several times until all air bubbles are expelled from the master cylinder bore and Bleeder Tubes. 6. Remove the Bleeder Tubes and Adapters from the master cylinder and plug the master cylinder outlet ports. 7. Install the fill cap on the reservoir. 8. Remove the master cylinder from the vise. 9. Install the master cylinder on the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 5042 Brake Bleeding: Service and Repair Base Brake Bleeding BASE BRAKE BLEEDING NOTE: For bleeding the ABS hydraulic system, refer to Antilock Brake System Bleeding in the Antilock Brake System. CAUTION: Before removing the master cylinder cap, wipe it clean to prevent dirt and other foreign matter from dropping into the master cylinder reservoir. CAUTION: Use only Mopar(R) brake fluid or an equivalent from a fresh, tightly sealed container. Brake fluid must conform to DOT 3 specifications. NOTE: For bleeding of the Antilock Brake System, Refer to BRAKES - ABS STANDARD PROCEDURE. Do not pump the brake pedal at any time while having a bleeder screw open during the bleeding process. This will only increase the amount of air in the system and make additional bleeding necessary. Do not allow the master cylinder reservoir to run out of brake fluid while bleeding the system. An empty reservoir will allow additional air into the brake system. Check the fluid level frequently and add fluid as needed. The following wheel circuit sequence for bleeding the brake hydraulic system should be used to ensure adequate removal of all trapped air from the hydraulic system. - Left rear wheel - Right front wheel - Right rear wheel - Left front wheel MANUAL BLEEDING NOTE: To bleed the brakes manually, the aid of a helper will be required. 1. Attach a clear plastic hose (1) to the bleeder screw and feed the hose into a clear jar (2) containing enough fresh brake fluid to submerge the end of the hose. 2. Have a helper pump the brake pedal three or four times and hold it in the down position. 3. With the pedal in the down position, open the bleeder screw at least one full turn. 4. Once the brake pedal has dropped, close the bleeder screw. After the bleeder screw is closed, release the brake pedal. 5. Repeat the above steps until all trapped air is removed from that wheel circuit (usually four or five times). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 5043 6. Bleed the remaining wheel circuits in the same manner until all air is removed from the brake system. Monitor the fluid level in the master cylinder reservoir (2) to make sure it does not go dry. 7. Check and adjust brake fluid level to the FULL mark. 8. Check the brake pedal travel. If pedal travel is excessive or has not been improved, some air may still be trapped in the system. Re-bleed the brakes as necessary. 9. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct. PRESSURE BLEEDING NOTE: Follow pressure bleeder manufacturer's instructions for use of pressure bleeding equipment. 1. Attach Master Cylinder Cap (2), Special Tool 6921, in place of the filler cap on the master cylinder reservoir (3). 2. Attach Bleeder Tank (1), Special Tool C-3496-B, or an equivalent, to the Master Cylinder Cap 6921. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 5044 3. Attach a clear plastic hose (1) to the bleeder screw and feed the hose into a clear jar (2) containing enough fresh brake fluid to submerge the end of the hose. 4. Open the bleeder screw at least one full turn or more to obtain a steady stream of brake fluid. 5. After approximately 120-240 ml (4-8 ounces) of fluid have been bled through the brake circuit and an air-free flow is maintained in the clear plastic hose and jar, close the bleeder screw. 6. Repeat this procedure at all the remaining bleeder screws. 7. Check and adjust brake fluid level to the FULL mark on the reservoir (2). 8. Check the brake pedal travel. If pedal travel is excessive or has not been improved, some air may still be trapped in the system. Re-bleed the brakes as necessary. 9. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 5045 Brake Bleeding: Service and Repair Antilock Brake System Bleeding ANTILOCK BRAKE SYSTEM BLEEDING The base brake's hydraulic system must be bled anytime air enters the hydraulic system. The ABS must always be bled anytime it is suspected that the HCU has ingested air. Brake systems with ABS must be bled as two independent braking systems. The non-ABS portion of the brake system with ABS is to be bled the same as any non-ABS system. The ABS portion of the brake system must be bled separately. Use the following procedure to properly bleed the brake hydraulic system including the ABS. NOTE: During the brake bleeding procedure, be sure the brake fluid level remains close to the FULL level in the master cylinder fluid reservoir. Check the fluid level periodically during the bleeding procedure and add Mopar(R) DOT 3 brake fluid as required. BLEEDING When bleeding the ABS system, the following bleeding sequence must be followed to insure complete and adequate bleeding. 1. Make sure all hydraulic fluid lines are installed and properly torqued. 2. Connect the scan tool to the diagnostics connector. The diagnostic connector is located under the lower steering column cover to the left of the steering column. 3. Using the scan tool, check to make sure the ABM does not have any fault codes stored. If it does, clear them. WARNING: When bleeding the brake system wear safety glasses. A clear bleed tube (1) must be attached to the bleeder screws and submerged in a clear container filled part way with clean brake fluid (2). Direct the flow of brake fluid away from yourself and the painted surfaces of the vehicle. Brake fluid at high pressure may come out of the bleeder screws when opened. NOTE: Pressure bleeding is recommended to bleed the base brake system to ensure all air is removed from system. Manual bleeding may also be used, but additional time is needed to remove all air from system. 4. Bleed the base brake system. 5. Using the scan tool, select ECU VIEW, followed by ABS MISCELLANEOUS FUNCTIONS to access bleeding. Follow the instructions displayed. When finished, disconnect the scan tool and proceed. 6. Bleed the base brake system a second time. Check brake fluid level in the reservoir periodically to prevent emptying, causing air to enter the hydraulic system. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 5046 7. Fill the master cylinder fluid reservoir (1) to the FULL level. 8. Test drive the vehicle to be sure the brakes are operating correctly and that the brake pedal does not feel spongy. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Removal Brake Pedal Assy: Service and Repair Removal BRAKE PEDAL NOTE: Refer to Warnings and Cautions connect and isolate the battery negative cable from its post on the battery. 2. If equipped, remove the silencer pad below the steering column opening cover. 3. Remove the steering column opening cover on the instrument panel. 4. Remove the reinforcement behind the steering column opening cover. 5. Disconnect the wiring connector (4) at the stop lamp switch (3). 6. Remove the stop lamp switch wiring routing clip (1) from the brake pedal bracket (2). 7. Remove the stop lamp switch (2) and discard it. Do not reuse the stop lamp switch. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Removal > Page 5051 8. Remove the retaining clip (2) securing the power brake booster push rod (1) to the brake pedal. To do so, position a small screwdriver under the center tang of the retaining clip, then rotate the screwdriver enough to allow the retaining clip tang to pass over the end of the brake pedal pin (3). Remove and discard the clip. Do not reuse the clip. 9. Slide the booster push rod (1) off the brake pedal pin (3). 10. Remove the four nuts (4) attaching the brake pedal (1) (and power brake booster) to the dash panel. 11. Remove the remaining nut (5) attaching the brake pedal (1) to the dash panel. 12. Remove the brake pedal (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Removal > Page 5052 Brake Pedal Assy: Service and Repair Installation BRAKE PEDAL 1. Carefully install the brake pedal and bracket assembly (1) in the vehicle lining up the bracket with the power brake booster mounting studs and the stud (2) on the dash panel. 2. Install the four nuts (4) attaching the brake pedal (1) (and power brake booster) to the dash panel. Do not tighten the nuts at this time. 3. Install the remaining nut (5) attaching the brake pedal (1) to the dash panel. To tighten this nut (and the other four from the preceding step), refer to the following step. CAUTION: Because of power brake booster design, it is very important to tighten the mounting nuts in the proper sequence. 4. Tighten the brake pedal/booster mounting nuts in the proper sequence to 23 Nm (17 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Removal > Page 5053 5. Using Mopar(R) Lubriplate, or an equivalent, coat the surface of the brake pedal pin (3) where it contacts the brake booster push rod (1). 6. Install the power brake booster push rod (1) on the pin (3) mounted on the side of the brake pedal. Install a NEW retaining clip (2) on the end of the pin. Do not reuse the old clip. CAUTION: Do not reuse the original stop lamp switch. The switch can only be adjusted once. That is during initial installation of the switch. If the switch is not adjusted properly or has been removed for some service, a new switch must be installed and adjusted. 7. Install and adjust a NEW stop lamp switch (2) in the brake pedal bracket (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Removal > Page 5054 8. If not already performed, connect the wiring connector (4) at the stop lamp switch (3). 9. Attach the stop lamp switch wiring routing clip (1) at the brake pedal bracket (2). 10. Install the steering column opening cover reinforcement in the steering column opening. 11. Install the steering column opening cover (and airbag if equipped) on the instrument panel. 12. If equipped, install the silencer pad below the instrument panel. 13. Connect the battery negative cable to its post on the battery. 14. Check the stop lamps to verify they are operating properly and not staying on when the pedal is in the released position. 15. Road test the vehicle to ensure proper operation of the brakes. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Testing and Inspection Brake Warning Indicator: Testing and Inspection BRAKE/PARK BRAKE INDICATOR The brake/park brake indicator illuminates when the parking brake is applied with the ignition switch turned to the ON position refer to the PARK BRAKE SWITCH TEST table). The same lamp will also illuminate if one of the two (hydraulic or ABS) service brake systems fail when the brake pedal is applied. TO TEST THE SYSTEM: - As the ignition switch is turned to the START position, the lamp should light. - Turn ignition switch to the ON position and apply the parking brake. The lamp should light. IF LAMPS FAILS TO LIGHT, INSPECT FOR: - A broken or disconnected wire at the switch - Defective switch - A burned out Light Emitting Diode (LED) - A damaged circuit board To test the service brake warning system, refer to Brakes, Diagnosis and Testing, Base Brake System Diagnosis Charts, Red Brake Warning Lamp. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures Brake Caliper: Procedures Cleaning CLEANING WARNING: Dust and dirt accumulating on brake parts during normal use may contain asbestos fibers from production or aftermarket brake linings. Breathing excessive concentrations of asbestos fibers can cause serious bodily harm. Exercise care when servicing brake parts. Do not sand or grind brake lining unless equipment used is designed to contain the dust residue. Do not clean brake parts with compressed air or by dry brushing. Cleaning should be done by dampening the brake components with a fine mist of water, then wiping the brake components clean with a dampened cloth. Dispose of cloth and all residue containing asbestos fibers in an impermeable container with the appropriate label. Follow practices prescribed by the Occupational Safety And Health Administration (OSHA) and the Environmental Protection Agency (EPA) for the handling, processing, and disposing of dust or debris that may contain asbestos fibers. To clean or flush the internal passages of the brake caliper, use fresh brake fluid or Mopar(R) Non-Chlorinated Brake Parts Cleaner. Never use gasoline, kerosene, alcohol, oil, transmission fluid or any fluid containing mineral oil to clean the caliper. These fluids will damage rubber cups and seals. Inspection INSPECTION Inspect the disc brake caliper for the following: - Brake fluid leaks in and around piston boot area - Ruptures, brittleness or damage to the piston dust boot If caliper fails inspection, disassemble and recondition caliper, replacing the seals and dust boots. Cleaning CLEANING WARNING: Dust and dirt accumulating on brake parts during normal use may contain asbestos fibers from production or aftermarket brake linings. Breathing excessive concentrations of asbestos fibers can cause serious bodily harm. Exercise care when servicing brake parts. Do not sand or grind brake lining unless equipment used is designed to contain the dust residue. Do not clean brake parts with compressed air or by dry brushing. Cleaning should be done by dampening the brake components with a fine mist of water, then wiping the brake components clean with a dampened cloth. Dispose of cloth and all residue containing asbestos fibers in an impermeable container with the appropriate label. Follow practices prescribed by the Occupational Safety And Health Administration (OSHA) and the Environmental Protection Agency (EPA) for the handling, processing, and disposing of dust or debris that may contain asbestos fibers. To clean or flush the internal passages of the brake caliper, use fresh brake fluid or Mopar(R) Non-Chlorinated Brake Parts Cleaner. Never use gasoline, kerosene, alcohol, oil, transmission fluid or any fluid containing mineral oil to clean the caliper. These fluids will damage rubber cups and seals. Inspection INSPECTION Inspect the disc brake caliper for the following: - Brake fluid leaks in and around boot area and inboard lining - Ruptures, brittleness or damage to the piston dust boot - Damaged, dry or brittle guide pin dust boots If caliper fails inspection, disassemble and recondition caliper, replacing the seals and dust boots. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5063 Brake Caliper: Removal and Replacement Removal REMOVAL NOTE: Refer to Warnings and Cautions. 1. Using a brake pedal holding tool as shown, depress the brake pedal past its first one inch (25 mm) of travel and hold it in this position. This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir when the lines are opened. 2. Raise and support the vehicle. 3. Remove the wheel mounting nuts (3), then the tire and wheel assembly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5064 4. Remove the banjo bolt (4) connecting the brake flex hose (2) to the brake caliper (5). There are two washers (3) that will come off with the banjo bolt. Discard the washers. NOTE: When removing the caliper guide pin bolts (2, 3) note that one (upper) has a special sleeve on the end. It is important that this bolt be installed in the upper mounting hole when the caliper is installed. 5. Remove the two brake caliper guide pin bolts (2, 3). 6. Slide the disc brake caliper (4) from the disc brake adapter bracket (1) and brake pads and remove. Installation INSTALLATION 1. Completely retract the caliper piston back into the bore of the caliper. Use a C-clamp to retract the piston. Place a wood block over the piston before installing the C-clamp to avoid damaging the piston. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5065 CAUTION: Use care when installing the caliper (4) onto the adapter bracket (1) to avoid damaging the guide pin boots. 2. Install the disc brake caliper over the brake pads on the brake caliper adapter bracket. NOTE: When installing the caliper guide pin bolts (2, 3) make sure that the one that has a special sleeve on the end is installed in the upper mounting hole. 3. Align the caliper guide pin bolt holes with the adapter bracket. Install the upper (with special sleeve) (2) and lower (3) caliper guide pin bolts. Tighten the guide pin bolts to 43 Nm (32 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5066 ERROR: undefined OFFENDING COMMAND: f‘~ STACK: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5067 Brake Caliper: Overhaul Disassembly DISASSEMBLY NOTE: Before disassembling the brake caliper, remove it from the vehicle. NOTE: Before disassembling the brake caliper, clean and inspect it. WARNING: Under no condition should high pressure air ever be used to remove a piston from a caliper bore. Personal injury could result from such a practice. CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will cause bore distortion. 1. Mount the caliper in a vise equipped with protective jaws. WARNING: Do not place face or hands near caliper and piston if using compressed air pressure to remove piston. Do not use high pressure. 2. Place a wooden block (1) in the caliper as shown. 3. If necessary, apply low pressure compressed air to the caliper fluid inlet in short spurts to force the piston out. 4. Remove the piston from the caliper. 5. Remove the dust boot from the piston and discard it. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5068 CAUTION: Do not use a screw driver or other metal tool for seal removal. Using such tools can scratch the bore or leave burrs on the seal groove edges. 6. Using a soft tool such as a plastic trim stick (1), work the piston seal (2) out of its groove in caliper piston bore. Discard the used seal. 7. Clean the piston bore and drilled passage ways with alcohol or a suitable solvent. Wipe it dry using only a lint-free cloth. 8. Inspect both the piston and bore for scoring or pitting. Bores that show light scratches or corrosion can usually be cleared of the light scratches or corrosion using crocus cloth. Assembly ASSEMBLY NOTE: Always have clean hands when assembling a brake caliper. NOTE: Always use fresh, clean brake fluid when assembling a brake caliper. NOTE: Never use an old piston seal. 1. Dip the NEW piston seal in clean brake fluid and install it in the groove (2) of the caliper bore. The seal (1) should be started at one area of the groove and gently worked around into the groove using only your clean fingers to seat it. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5069 2. Coat the NEW piston with clean brake fluid. 3. Coat the NEW piston boot with clean brake fluid leaving a generous amount inside the boot. 4. Position the dust boot over the lower section of the piston. 5. Extend the dust boot below the bottom of the piston and guide the lip seal into the groove in the caliper piston bore. CAUTION: Force applied to the piston (1) to seat it in the bore must be applied uniformly to avoid cocking and binding of the piston. 6. Install the piston (1) into the bore, carefully pushing it past the piston seal using hand pressure. Push the piston in until it bottoms in the caliper bore and the dust boot lip seal falls into the groove near the top of the piston. 7. Install the caliper on the vehicle and bleed the brakes as necessary. Disassembly DISASSEMBLY NOTE: Before disassembling the brake caliper, remove it from the vehicle. NOTE: Before disassembling the brake caliper, clean and inspect it. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5070 1. With finger tip, trace around the outside perimeter of the piston dust boot to find the ends of the boot snap-ring. 2. Using a small screwdriver (2) or like tool, carefully remove the boot snap-ring (1) making sure not to damage the dust boot, piston or piston bore. 3. Carefully pull the piston dust boot away from the caliper boot groove. WARNING: Under no condition should high pressure air ever be used to remove a piston from a caliper bore. Personal injury could result from such a practice. CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will cause bore distortion. 4. Mount the caliper in a vise equipped with protective jaws. WARNING: Do not place face or hands near caliper and piston if using compressed air pressure to remove piston. Do not use high pressure. 5. Place a wooden block (2) in the caliper as shown. 6. As necessary, apply low pressure compressed air to the caliper fluid inlet in short spurts to force the piston (1) out. 7. Remove the piston (with dust boot) from the caliper. 8. Remove the dust boot from the piston and discard it. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5071 CAUTION: Do not use a screw driver or other metal tool for seal removal. Using such tools can scratch the bore or leave burrs on the seal groove edges. 9. Using a soft tool such as a plastic trim stick (2), work the piston seal (1) out of its groove (3) in the caliper piston bore. Discard the used seal. 10. Clean the piston bore and drilled passage ways with alcohol or a suitable solvent. Wipe it dry using only a lint-free cloth. 11. Inspect both the piston and bore for scoring or pitting. Bores that show light scratches or corrosion can usually be cleared of the light scratches or corrosion using crocus cloth. Assembly ASSEMBLY NOTE: Always have clean hands when assembling a brake caliper. NOTE: Always use fresh, clean brake fluid when assembling a brake caliper. NOTE: Never use an old piston seal. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5072 1. Dip the NEW piston seal in clean brake fluid and install it in the groove (2) of the caliper piston bore. The seal (1) should be started at one area of the groove and gently worked around into the groove using only clean finger tips to seat it. 2. Coat the NEW piston dust boot (1) with clean brake fluid leaving a generous amount inside the boot. 3. Position the dust boot over the top of the piston (2) and into the piston groove. Make sure the side of the dust boot with the outer lip (3) for the boot snap-ring is positioned upward as shown. 4. Coat the piston with clean brake fluid. CAUTION: Force applied to the piston to seat it in the bore must be applied uniformly to avoid cocking and binding of the piston. 5. Insert the piston into the caliper bore, carefully pushing it past the piston seal using hand pressure. Push the piston in until it bottoms in the caliper bore. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5073 6. With finger tips, seat the dust boot lip (1) into the boot groove in the caliper bore. Trace around the outside perimeter of the dust boot with a finger tip making sure the lip is properly seated in the groove and not much air is trapped behind the boot. 7. Position one end of the boot snap-ring (1) inside the boot outer lip (2), then making a circular motion, walk the snap-ring around the boot lip, completely installing and seating it. 8. Inspect whether the two ends of the boot snap-ring are not overlapping one another. If they are, push the snap ring and dust boot further into groove removing any overlap of the snap-ring. 9. Install the caliper on the vehicle and bleed the brakes as necessary. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications Brake Pad: Specifications Measure brake pad minimum thickness. Brake pads must be replaced when usable material on a brake pad lining measured at its thinnest point measures one millimeter (0.04 inches) or less. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures Brake Pad: Procedures Cleaning CLEANING WARNING: Dust and dirt accumulating on brake parts during normal use may contain asbestos fibers from production or aftermarket brake linings. Breathing excessive concentrations of asbestos fibers can cause serious bodily harm. Exercise care when servicing brake parts. Do not sand or grind brake lining unless equipment used is designed to contain the dust residue. Do not clean brake parts with compressed air or by dry brushing. Cleaning should be done by dampening the brake components with a fine mist of water, then wiping the brake components clean with a dampened cloth. Dispose of cloth and all residue containing asbestos fibers in an impermeable container with the appropriate label. Follow practices prescribed by the Occupational Safety And Health Administration (OSHA) and the Environmental Protection Agency (EPA) for the handling, processing, and disposing of dust or debris that may contain asbestos fibers. Inspection INSPECTION Visually inspect brake pads for uneven lining wear. Also inspect for excessive lining deterioration. Check the clearance between the tips of the wear indicators (if equipped) on the pads and the brake rotors. If a visual inspection does not adequately determine the condition of the lining, a physical check will be necessary. To check the amount of lining wear, remove the disc brake pads from the vehicle. Measure brake pad minimum thickness. Brake pads must be replaced when usable material on a brake pad lining measured at its thinnest point measures one millimeter (0.04 inches) or less. NOTE: It is important to inspect both front and rear brake pads during the same inspection. Typically, front and rear brake pads wear out at the same time. Replace both disc brake pads (inboard and outboard) at each caliper. It is also necessary to replace the pads on the opposite side of the vehicle as well as the pads failing inspection to maintain proper braking characteristics. If the brake pad assemblies do not require replacement, be sure to reinstall the brake pads in the original position they were removed from. Cleaning CLEANING WARNING: Dust and dirt accumulating on brake parts during normal use may contain asbestos fibers from production or aftermarket brake linings. Breathing excessive concentrations of asbestos fibers can cause serious bodily harm. Exercise care when servicing brake parts. Do not sand or grind brake lining unless equipment used is designed to contain the dust residue. Do not clean brake parts with compressed air or by dry brushing. Cleaning should be done by dampening the brake components with a fine mist of water, then wiping the brake components clean with a dampened cloth. Dispose of cloth and all residue containing asbestos fibers in an impermeable container with the appropriate label. Follow practices prescribed by the Occupational Safety And Health Administration (OSHA) and the Environmental Protection Agency (EPA) for the handling, processing, and disposing of dust or debris that may contain asbestos fibers. Inspection INSPECTION Visually inspect brake pads for uneven lining wear. Also inspect for excessive lining deterioration. Check the clearance between the tips of the wear indicators (if equipped) on the pads and the brake rotors. If a visual inspection does not adequately determine the condition of the lining, a physical check will be necessary. To check the amount of lining wear, remove the disc brake pads from the vehicle. Measure brake pad minimum thickness. Brake pads must be replaced when usable material on a brake pad lining measured at its thinnest point measures one millimeter (0.04 inches) or less. NOTE: It is important to inspect both front and rear brake pads during the same inspection. Typically, front and rear brake pads wear out at the same time. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 5079 Replace both disc brake pads (inboard and outboard) at each caliper. It is also necessary to replace the pads on the opposite side of the vehicle as well as the pads failing inspection to maintain proper braking characteristics. If the brake pad assemblies do not require replacement, be sure to reinstall the brake pads in the original position they were removed from. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 5080 Brake Pad: Removal and Replacement Removal REMOVAL NOTE: Refer to Warnings and Cautions. 1. Raise and support the vehicle. NOTE: Perform STEP 2 through STEP 5 on each side of the vehicle to complete pad set removal. 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). NOTE: When removing the caliper guide pin bolts (2, 3) note that one (upper) has a special sleeve on the end. It is important that this bolt be installed in the upper mounting hole when the caliper is installed. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 5081 3. Remove the two brake caliper guide pin bolts (2, 3). 4. Remove the disc brake caliper (4) from the disc brake adapter bracket (1) and hang it out of the way using wire or a bungee cord. Use care not to overextend the brake hose when doing this. 5. Remove the brake pads (4, 5) from the caliper adapter bracket (2). Installation INSTALLATION NOTE: Perform STEP 1 through STEP 5 on each side of the vehicle to complete pad set installation, then proceed to STEP 6. NOTE: Make sure that the audible wear indicators (if equipped) are placed toward the top when the inboard brake pads are installed on each side of the vehicle. 1. Place the brake pads (4, 5) in the abutment shims (3) clipped into the disc brake caliper adapter bracket (2) as shown. Place the pad with the wear indicator attached on the inboard side (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 5082 2. Completely retract the caliper piston back into the bore of the caliper. CAUTION: Use care when installing the caliper (4) onto the adapter bracket (1) to avoid damaging the boots. 3. Install the disc brake caliper over the brake pads on the brake caliper adapter bracket. NOTE: When installing the caliper guide pin bolts (2, 3) make sure that the one that has a special sleeve on the end is installed in the upper mounting hole. 4. Align the caliper guide pin bolt holes with the adapter bracket. Install the upper (with special sleeve) (2) and lower (3) caliper guide pin bolts. Tighten the guide pin bolts to 43 Nm (32 ft. lbs.). 5. Install tire and wheel assembly (1). Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 6. Lower the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 5083 7. Pump the brake pedal several times before moving the vehicle to set the pads to the brake rotor. 8. Check and adjust the brake fluid level in the reservoir (2) as necessary. 9. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake pads. Removal REMOVAL NOTE: Refer to Warnings and Cautions. NOTE: If the rear brake pads are being replaced due to a howl or moan while driving in reverse, proper diagnosis and correction is essential. 1. Raise and support the vehicle. NOTE: Perform STEP 2 through STEP 6 on each side of the vehicle to complete pad set removal. 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). NOTE: In some cases, it may be necessary to retract the caliper piston in its bore a small amount in order to provide sufficient clearance between the pads and the rotor to easily remove the caliper from the knuckle. This can usually be accomplished before the guide pin bolts are removed, by grasping the rear of the caliper and pulling outward working with the guide pins, thus retracting the piston. Never push on the piston directly as it may get damaged. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 5084 3. Remove the disc brake caliper (2) lower guide pin bolt (1). CAUTION: When moving rear brake caliper upward, use extreme care not to damage or overextend the flex hose. Damage may occur. 4. Rotate the caliper (1) upward hinging off the upper guide pin bolt. Rotate the caliper upward just enough to allow brake pad removal. Hang the caliper assembly in this position using wire or a bungee cord. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 5085 5. Remove the inboard brake pad (5) from the caliper adapter bracket (3). 6. Remove the outboard brake pad (2) from the caliper (1) by prying the brake pad retaining clip over the raised area on the caliper. Slide the brake pad off of the brake caliper. Installation INSTALLATION NOTE: If the rear pads are being replaced due to a howl or moan while driving in reverse, proper diagnosis and correction is essential. NOTE: Perform STEP 1 through STEP 6 on each side of the vehicle to complete pad set installation, then proceed to STEP 7. 1. Completely retract the caliper piston back into the piston bore of the caliper. This is required to gain the necessary pad-to-rotor clearance for the caliper installation onto the steering knuckle. NOTE: Place the brake pad with the audible wear indicator attached on the inboard side. The audible wear indicator should be positioned at the bottom when installed. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 5086 2. Slide the outboard brake pad (2) onto the caliper (1). Be sure the retaining clip is squarely seated in the depressed areas on the caliper beyond the raised retaining bead. 3. Place the inboard brake pad (5) in the abutment shims (4) clipped into the disc brake caliper adapter bracket (3) as shown (see preceding note). CAUTION: Use care when installing the caliper onto the adapter bracket to avoid damaging the guide pin boot. 4. Rotate the disc brake caliper downward over the brake rotor and lower part of caliper adapter. 5. Install the disc brake caliper (2) lower guide pin bolt (1). Tighten the guide pin bolt to 43 Nm (32 ft. lbs.). NOTE: Once the caliper is installed, inspect the outboard brake pad to make sure it is correctly positioned. The retaining clip (2) must be squarely seated in the depressed areas (1) on the caliper fingers. Also, the nubs on the pad's steel backing plate must be fully seated in the depressions formed into the inside of the caliper fingers. There should be no gap between the pad backing plate and the caliper fingers. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 5087 6. Install tire and wheel assembly (1). Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 7. Lower the vehicle. 8. Pump the brake pedal several times to ensure the vehicle has a firm brake pedal before moving the vehicle. 9. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake pads. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications Brake Rotor/Disc: Specifications BRAKE ROTOR LIMITS/SPECIFICATIONS NOTE: When refacing a rotor, the required TIR (Total Indicator Reading) and thickness variation limits MUST BE MAINTAINED. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 5091 Brake Rotor/Disc: Testing and Inspection BRAKE ROTOR Any servicing of the rotor requires extreme care to maintain the rotor within service tolerances to ensure proper brake action. Excessive runout or wobble in a rotor can increase pedal travel due to piston knock-back. This increases guide pin sleeve wear due to the tendency of the caliper to follow the rotor wobble. When diagnosing a brake noise or pulsation, the machined disc braking surface should be inspected. BRAKING SURFACE INSPECTION Light braking surface scoring and wear is acceptable. If heavy scoring or warping is evident, the rotor must be refaced or replaced. Excessive wear and scoring of the rotor can cause improper lining contact on the rotor's braking surface. If the ridges on the rotor are not removed before new brake shoes are installed, improper wear of the shoes will result. If a vehicle has not been driven for a period of time, the rotor's braking surface will rust in the areas not covered by the brake shoes at that time. Once the vehicle is driven, noise and chatter from the disc brakes can result when the brakes are applied. Some discoloration or wear of the rotor surface is normal and does not require resurfacing when linings are replaced. If cracks or burned spots are evident, the rotor must be replaced. ROTOR MINIMUM THICKNESS Measure rotor thickness (1) at the center of the brake pad contact surface. Replace the rotor if it is worn below minimum thickness or if machining the rotor will cause its thickness to fall below specifications. CAUTION: Do not machine the rotor if it will cause the rotor to fall below minimum thickness. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 5092 On front rotors, Minimum thickness specifications (2) are cast on the rotor's unmachined surface on the inside of the rotor (1). Limits can also be found in this component's specification table. On rear rotors, Minimum thickness specifications (3) are cast into the rotor's unmachined surface on the outside of the rotor (1). This area also shows the maximum thickness specifications (2) for the hat section of the rotor. Limits can also be found in this component's specification table. ROTOR THICKNESS VARIATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 5093 Thickness variation in a rotor's braking surface can result in pedal pulsation, chatter and surge. This can also be caused by excessive runout in the rotor or the hub. Rotor thickness variation measurements should be made in conjunction with measuring runout. Measure thickness of the brake rotor (2) at 12 equal points around the rotor braking surface with a micrometer (1) at a radius approximately 25 mm (1 inch) from edge of rotor. If thickness measurements vary beyond the specification listed in the specification table. ROTOR RUNOUT On-vehicle rotor runout is the combination of the individual runout of the hub face and the runout of the brake rotor (hub runout can be measured separately). To measure rotor runout on the vehicle: 1. Raise and support the vehicle. 2. Remove the tire and wheel assembly. 3. Install standard wheel mounting nuts, flat side to rotor, on all the wheel studs (2). Progressively tighten the nuts in a crisscross pattern to 135 Nm (100 ft. lbs.). 4. Mount Dial Indicator (1), Special Tool C-3339A, with Wheel, Special Tool 25w, or equivalent, to the knuckle. Position the dial indicator wheel to contact the rotor braking surface approximately 10 mm (0.39 in.) from the outer edge of the rotor (3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 5094 5. Slowly rotate the brake rotor checking lateral runout, marking the low and high spots. Record these measurements. 6. Check and record the runout on the opposite side of the rotor in the same fashion, marking the low and high spots. 7. Compare runout measurement to specifications. 8. If runout is in excess of specifications, check the lateral runout of the hub face. Before removing the rotor from the hub, place a chalk mark across both the rotor (1) and the one wheel stud (2) closest to where the high runout measurement was taken. This way, the original mounting spot of the rotor on the hub is indexed. 9. Remove the rotor from the hub. NOTE: Before measuring hub runout, clean the hub face surface with an appropriate cleaner. This provides a clean surface to get an accurate indicator reading. 10. Mount Dial Indicator (2), Special Tool C-3339A, to the knuckle. Position the dial indicator stem so it contacts the hub face (1) near the outer diameter. Care must be taken to position the stem outside of the stud circle, but inside of the chamfer on the hub rim. 11. Slowly rotate the hub measuring runout. Hub runout should not exceed 0.08 mm (0.003 inch). If runout exceeds this specification, the hub must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 5095 12. If hub runout does not exceed this specification, install the original rotor back on the hub, aligning the chalk mark on the rotor (2) with a wheel mounting stud, two studs apart from the original stud (1). 13. Install standard wheel mounting nuts, flat side to rotor, on all the wheel studs (2). Progressively tighten the nuts in a crisscross pattern to 135 Nm (100 ft. lbs.). 14. Mount the Dial Indicator (1), Special Tool C-3339A, and remeasure runout on both sides of the brake rotor as explained in earlier steps to see if runout is now within specifications. 15. If runout is still not within specifications, reface or replace brake rotor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures Brake Rotor/Disc: Procedures BRAKE ROTOR MACHINING NOTE: Refacing the rotor is not required each time the brake pads are replaced, only when the need is foreseen. Any servicing of the rotor requires extreme care to maintain the rotor within service tolerances to ensure proper brake action. If the rotor surface is deeply scored or warped, or there is a complaint of brake roughness or brake pedal pulsation, the rotor should be refaced using a hub-mounted on-car brake lathe (1), or replaced. The use of a hub-mounted on-car brake lathe (1) is highly recommended to eliminate the possibility of excessive runout. It trues the brake rotor to the vehicle's hub and bearing. NOTE: All brake rotors (1) have markings for minimum allowable thickness cast on an unmachined surface of the rotor (2) or stamped into the hat section. On this vehicle, the minimum thickness specification for the front brake rotor is located on the inside of the rotor. The minimum thickness specification for the rear brake rotor is located on the outside of the rotor. Minimum thickness specifications can also be found in this component's specification table. Minimum allowable thickness is the minimum thickness which the brake rotor machined surface may be cut to. CAUTION: Do not machine the rotor if it will cause the rotor to fall below minimum thickness. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 5098 Before lathe installation, verify the brake rotor face and the hub adapters are free of any chips, rust, or contamination. When mounting and using the brake lathe, strict attention to the brake lathe manufacturer's operating instructions is required. Machine both sides of the brake rotor at the same time. Cutting both sides at the same time minimizes the possibility of a tapered or uneven cut. When refacing a rotor, the required TIR (Total Indicator Reading) and thickness variation limits MUST BE MAINTAINED. Extreme care in the operation of rotor turning equipment is required. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 5099 Brake Rotor/Disc: Removal and Replacement Front Brake Rotor FRONT BRAKE ROTOR NOTE: Refer to Warnings and Cautions. 1. Raise and support the vehicle. 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). NOTE: In some cases, it may be necessary to retract the caliper piston in its bore a small amount in order to provide sufficient clearance between the pads and the rotor to easily remove the caliper from the knuckle. This can usually be accomplished before the guide pin bolts are removed, by grasping the inboard side of the caliper and pulling outward working with the guide pins, thus retracting the piston. Never push on the piston directly as it may get damaged. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 5100 3. Remove the two bolts (3) securing disc brake caliper and adapter bracket (1) to the steering knuckle (2). 4. Remove the disc brake caliper and adapter bracket (1) from the knuckle (2) and rotor (4) as an assembly. Hang the assembly out of the way using wire or a bungee cord. Use care not to overextend the brake hose when doing this. 5. Remove any clips (3) retaining the brake rotor (2) to the wheel studs. 6. Slide the brake rotor (2) off the hub and bearing (1). Rear Brake Rotor REAR BRAKE ROTOR NOTE: Refer to Warnings and Cautions. 1. Raise and support the vehicle. 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly. NOTE: In some cases, it may be necessary to retract the caliper piston in its bore a small amount in order to provide sufficient clearance Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 5101 between the pads and the rotor to easily remove the caliper from the knuckle. This can usually be accomplished before the guide pin bolts are removed, by grasping the inboard side of the caliper and pulling outward working with the guide pins, thus retracting the piston. Never push on the piston directly as it may get damaged. 3. Remove the disc brake caliper (2) lower guide pin bolt (1). CAUTION: When moving rear brake caliper upward, use extreme care not to damage or overextend the flex hose. Damage may occur. 4. Rotate the caliper upward hinging off the upper guide pin bolt. Rotate the caliper upward just enough to allow brake rotor removal. Hang the caliper assembly in this position using wire or a bungee cord. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 5102 5. Remove any clips (2) retaining the brake rotor (3) to the wheel studs. 6. Slide the brake rotor (3) off the hub and bearing (1) and remove. Front Brake Rotor FRONT BRAKE ROTOR NOTE: Inspect disc brake pads before installation. 1. Clean the hub face (1) to remove any dirt or corrosion where the rotor mounts. 2. Install the brake rotor (2) over the studs on the hub and bearing. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 5103 3. Install the disc brake caliper and adapter bracket assembly (1) over the brake rotor (4) and knuckle (2). 4. Install the mounting bolts (3) securing the caliper adapter bracket to the knuckle (2). Tighten the bolts to 108 Nm (80 ft. lbs.). 5. Install the tire and wheel assembly (1). Tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 6. Lower the vehicle. 7. Pump the brake pedal several times before moving the vehicle to set the pads to the brake rotor. 8. Check and adjust the brake fluid level in the reservoir as necessary. 9. Road test the vehicle and make several stops to seat the brake pads to the rotor. Rear Brake Rotor REAR BRAKE ROTOR NOTE: Inspect disc brake pads and parking brake shoes before installation. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 5104 1. Clean the hub face (1) to remove any dirt or corrosion where the rotor mounts. 2. Install the brake rotor (3) over the studs on the hub and bearing (1). CAUTION: Use care when installing the caliper onto the adapter bracket to avoid damaging the guide pin boot. 3. Rotate the disc brake caliper downward over the brake rotor and lower part of caliper adapter. 4. Install the disc brake caliper (2) lower guide pin bolt (1). Tighten the guide pin bolt to 43 Nm (32 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 5105 NOTE: Once the caliper is installed, inspect the outboard brake pad to make sure it is correctly positioned. The retaining clip (2) must be squarely seated in the depressed areas (1) on the caliper fingers. Also, the nubs on the pad's steel backing plate must be fully seated in the depressions formed into the inside of the caliper fingers. There should be no gap between the pad backing plate and the caliper fingers. 5. Install tire and wheel assembly (1). Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 6. Lower the vehicle. 7. Pump the brake pedal several times before moving the vehicle to set the pads to the brake rotor. 8. Check and adjust the brake fluid level in the reservoir as necessary. 9. Road test the vehicle and make several stops to seat the brake pads to the rotor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair > Removal Backing Plate: Service and Repair Removal REMOVAL NOTE: Refer to Warnings and Cautions. 1. Using a brake pedal holding tool as shown, depress the brake pedal past its first one inch of travel and hold it in this position. This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir. 2. Raise and support the vehicle. 3. Remove the wheel mounting nuts (3), then the tire and wheel assembly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair > Removal > Page 5111 4. Access and remove the drum brake shoes (6) from the support plate (2). 5. Position a 10 mm box wrench (2) over the retainer fingers on the end of the parking brake cable housing (1). Compress the cable housing retaining fingers with the wrench, then pull the cable housing out of the support plate. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair > Removal > Page 5112 6. Disconnect the brake tube (2) at the wheel cylinder. 7. Remove the wheel cylinder attaching screws (1). 8. Remove the wheel cylinder from the support plate. 9. If equipped with a wheel speed sensor, remove the screw (1) fastening the wheel speed sensor head (3) in the rear of the hub and bearing (2). Remove the sensor head from the hub and bearing. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair > Removal > Page 5113 10. Remove the four bolts (8) securing the hub and bearing (5), support plate (2), and spacer (7) to the trailing link (1). 11. Remove the hub and bearing (3), support plate (2), and spacer (1) as an assembly from the trailing link. Separate the spacer and hub and bearing from the support plate once removed. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair > Removal > Page 5114 Backing Plate: Service and Repair Installation INSTALLATION 1. Assemble the hub and bearing (3) through the support plate (2) and install the spacer (1) on the rear of the assembly. 2. Install the hub and bearing (3), support plate (2), and spacer (1) as an assembly on the trailing link. NOTE: When performing the following step, use NEW mounting bolts or clean and apply Mopar(R) Stud & Bearing Mount Adhesive or equivalent to the original mounting bolt threads before reuse. 3. Install the four bolts (8) securing the hub and bearing (5), support plate (2), and spacer (7) to the trailing link (1). Tighten the mounting bolts to 105 Nm (77 ft. lbs.). 4. Insert the parking brake cable into its mounting hole in the brake support plate. Push the cable housing in until the retainer's fingers lock into place. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair > Removal > Page 5115 5. If equipped with a wheel speed sensor, Install the wheel speed sensor head (3) into the rear of the hub and bearing (2). Install the wheel speed sensor head mounting screw (1). Tighten the screw to 10 Nm (89 in. lbs.). 6. Install the wheel cylinder onto the brake support plate. Install and tighten the mounting screws (1) to 13 Nm (115 in. lbs.). 7. Connect the brake tube (2) to the wheel cylinder (1). Tighten the tube nut to 17 Nm (150 in. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair > Removal > Page 5116 8. Lubricate shoe contact areas on support plate and anchor using Mopar(R) Brake Lubricant or equivalent. NOTE: Inspect the brake shoes before installation. 9. Install the drum brake shoes (6) and drum (4). Adjust shoes as necessary. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair > Removal > Page 5117 10. Install the tire and wheel assembly (1). Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 11. Slowly rotate the rear wheel and verify that the brake drum lightly drags on the shoes. 12. Lower the vehicle. 13. Remove the brake pedal holding tool. 14. Bleed the affected wheel cylinder as necessary. 15. Road test the vehicle to ensure proper brake operation. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications Brake Drum: Specifications BRAKE DRUM With the drum off the vehicle, measure the drum for diameter variation (oval shape). The diameter variation of the drum braking surface must not exceed specifications listed in the following table. Measure brake drum runout. Brake drum runout should be checked with the drum mounted on a brake lathe. Brake drum runout should not exceed specifications listed in the following table. If either of these measurements are not within specification, reface or replace the drum.. Always replace the drum if machining will cause the diameter to exceed drum maximum diameter. All brake drums (2) are marked on the inside with the maximum allowable brake drum diameter (1). Maximum brake drum diameter can also be found in the following table. Brake Drum Limits Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 5121 Brake Drum: Testing and Inspection BRAKE DRUM With the drum off the vehicle, measure the drum for diameter variation (oval shape). The diameter variation of the drum braking surface must not exceed specifications listed in the following table. Measure brake drum runout. Brake drum runout should be checked with the drum mounted on a brake lathe. Brake drum runout should not exceed specifications listed in the following table. If either of these measurements are not within specification, reface or replace the drum.. Always replace the drum if machining will cause the diameter to exceed drum maximum diameter. All brake drums (2) are marked on the inside with the maximum allowable brake drum diameter (1). Maximum brake drum diameter can also be found in the following table. Brake Drum Limits Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Procedures Brake Drum: Procedures BRAKE DRUM MACHINING If a brake drum is deeply scored or warped, it can be machined on a brake lathe equipped to machine brake drums. Follow the manufacturers instructions on the machining procedure. Measure the brake drum diameter before machining. If machining the drum will cause the drum to exceed maximum allowable diameter, do not machine the brake drum. It needs to be replaced. CAUTION: Do not machine the brake drum if it will cause the drum to exceed maximum allowable diameter. All brake drums (2) are marked with the maximum allowable brake drum diameter. All vehicles have it marked on the inside of the drum (1). When machining, make sure the feed rate for the final cut is set to deliver a fine finish. A fine finish helps to avoid a screw effect on the brake shoes when the brakes are applied. This final feed cut specification varies from lathe manufacturer to lathe manufacturer. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Procedures > Page 5124 Brake Drum: Removal and Replacement Removal REMOVAL NOTE: Refer to Warnings and Cautions. 1. Raise vehicle. 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly. 3. Slide the brake drum (4) off the wheel mounting studs of the hub and bearing (5) and remove it from the vehicle. If the drum does not come off, further brake clearance can be obtained by backing off the brake adjuster screw. To do so, perform the following procedure. BACKING OFF SHOE ADJUSTMENT Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Procedures > Page 5125 1. Remove the plug from the rear of the support plate below the wheel cylinder. 2. Insert a small screwdriver through the access hole (2) in the support plate, under the adjuster, against the lever pawl. The pawl is attached to and pivots from the rear brake shoe. 3. While pushing on the pawl with the screwdriver to disengage it from the adjuster wheel teeth, rotate the wheel (1) upward to back off the adjustment using another screwdriver or a brake adjuster tool. 4. Once the adjuster screw is backed off a sufficient amount, slide the drum off the wheel mounting studs. Installation INSTALLATION NOTE: Before installing drum, inspect brake shoe linings for wear, alignment, and contamination. Repair or replace as necessary. NOTE: If rust or any foreign material is present on hub, drum or wheel mating surfaces, wet wire brush these areas to remove prior to assembly of parts. 1. Properly remove any buildup formed along outer edge of drum's machined braking surface. 2. Adjust the brake shoes-to-drum diameter using a brake shoe gauge. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Procedures > Page 5126 3. Slide the brake drum (4) onto the wheel mounting studs on the hub and bearing (5). 4. Install the tire and wheel assembly (1). Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 5. Lower the vehicle. 6. Road test the vehicle stopping in both forward and reverse directions. The automatic-adjuster will continue to adjust the brakes as necessary during the road test. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Adjustments Brake Shoe: Adjustments DRUM BRAKE SHOE ADJUSTMENT NOTE: Refer to Warnings and Cautions. 1. Verify the parking brake lever is in the fully released position. 2. Raise and support the vehicle. NOTE: Perform the following steps on each rear drum brake assembly as necessary. 3. Remove the wheel mounting nuts (3), then the rear tire and wheel assembly. 4. Remove the brake drum (4). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Adjustments > Page 5130 5. Using a Brake Shoe Gauge (1), Special Tool C-3919 or equivalent, measure the inside diameter of the brake drum at the center of the shoe contact area. Tighten the Gauge setscrew at this measurement. 6. Place the opposite side of the brake shoe gauge (2) over the brake shoes (1) as shown. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Adjustments > Page 5131 7. Adjust the shoe diameter to the setting on the gauge. To adjust the shoe diameter, turn the adjuster wheel using a screwdriver inserted through the adjusting hole in the rear of the shoe support plate. Once the tip of the screwdriver contacts the adjuster wheel teeth, move the handle of tool upward using the support plate as a pivot to adjust the shoes outward. 8. If at any time the adjustment needs to be backed off, perform the following: a. Remove the plug from the rear of the support plate below the wheel cylinder. b. Insert a small screwdriver through the access hole (2) in the support plate, under the adjuster, against the lever pawl. The pawl is attached to and pivots from the rear brake shoe. c. While pushing on the pawl with the screwdriver to disengage it from the adjuster wheel teeth, rotate the wheel (1) upward to back off the adjustment using another screwdriver or a brake adjuster tool. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Adjustments > Page 5132 9. Once the shoe diameter is set, remove the tool and install the brake drum (4). 10. Turn the brake drum. A slight drag should be felt while rotating the drum. If not, repeat the above procedure. 11. Install the tire and wheel assembly (1). Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 12. After adjusting both rear drum brakes as necessary, lower the vehicle. 13. Apply and release the parking brake lever one time after the adjustment process is completed checking parking brake operation. 14. Road test the vehicle stopping in both forward and reverse directions. The automatic-adjuster will continue to adjust the brakes as necessary during the road test. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Procedures Brake Shoe: Procedures Cleaning CLEANING WARNING: Dust and dirt accumulating on brake parts during normal use may contain asbestos fibers from production or aftermarket brake linings. Breathing excessive concentrations of asbestos fibers can cause serious bodily harm. Exercise care when servicing brake parts. Do not sand or grind brake lining unless equipment used is designed to contain the dust residue. Do not clean brake parts with compressed air or by dry brushing. Cleaning should be done by dampening the brake components with a fine mist of water, then wiping the brake components clean with a dampened cloth. Dispose of cloth and all residue containing asbestos fibers in an impermeable container with the appropriate label. Follow practices prescribed by the Occupational Safety And Health Administration (OSHA) and the Environmental Protection Agency (EPA) for the handling, processing, and disposing of dust or debris that may contain asbestos fibers. Inspection INSPECTION Inspect the shoe linings. Rear brake shoe linings should show contact across the entire width of the lining and also from the heel to the toe of the lining. Replace the shoes if noted otherwise. Brake shoes with lack of contact at the toe or heel of the brake shoe lining may be improperly ground. Clean and inspect the brake support plate and shoe adjuster screw. Apply a thin coat of Mopar(R) Multi-Purpose Grease or equivalent to the threads of the self-adjuster. Replace the adjuster screw if it is corroded. NOTE: Adjuster screws are different side-to-side. Left side adjuster screws have left-hand threads and right side adjuster screws have right-hand threads. Inspect the return springs and hold-down spring clips. If the existing brake shoe return springs or hold-down spring clips have been overheated or damaged, replace them. Overheating indications are paint discoloration or distorted end coils. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Procedures > Page 5135 Brake Shoe: Removal and Replacement Removal REMOVAL NOTE: Refer to Warnings and Cautions. NOTE: Make sure parking brake is in "released" position before raising vehicle. 1. Raise and support the vehicle. NOTE: Perform STEP 2 through STEP 16 on each side of the vehicle to complete shoe set removal. It may be easier to install the new components on the first side of the vehicle before disassembling the opposite side so it may be used as a reference guide for proper installation. 2. Remove the wheel mounting nuts (3), then the rear tire and wheel assembly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Procedures > Page 5136 3. Remove the brake drum (4). 4. Remove the lower shoe spring (3). 5. Compress and remove the hold-down spring (4) retaining the rear shoe to the support plate. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Procedures > Page 5137 6. Pull the rear shoe (4) away from the anchor (3) allowing better access to the parking brake cable (2) connection at the lever (1). 7. Compress the cable return spring, then remove the parking brake cable from the parking brake lever. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Procedures > Page 5138 8. Compress and remove the hold-down spring (2) retaining the front shoe to the support plate. 9. Remove both brake shoes from the wheel cylinder. 10. Remove both shoes and remaining parts as an assembly (3) through the opening between the wheel cylinder (1) and support plate hub and bearing. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Procedures > Page 5139 11. Place the shoe assembly outboard-side-up on a flat surface. 12. Remove the adjuster spring (2) from the leading shoe (3) and the lever pawl (1). 13. Remove the lever pawl (1) from the pivot on the rear shoe (5). 14. Flip the shoe assembly over to show the inboard side. 15. Remove the upper shoe return spring (1). 16. Remove the adjuster (5) from the shoes and parking brake lever (2). Installation INSTALLATION NOTE: Perform STEP 1 through STEP 21 on each side of vehicle to complete shoe set installation, then proceed to STEP 22. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Procedures > Page 5140 1. Lubricate shoe contact areas on support plate and anchor using Mopar(R) Brake Lubricant or equivalent. 2. Lubricate the adjuster screw threads with Mopar(R) Brake Lubricant or equivalent. Turn adjuster wheel in until it is completely seated. NOTE: Right side drum brake shown. Left side is a mirror image. 3. Place one front shoe (6) and one rear shoe (3) inboard-side-up on a flat surface. (rear shoe has parking brake lever attached to it). 4. Install the adjuster (5), adjuster wheel toward the rear, between the two brake shoes. Make sure the wide notch in the rear fork aligns with the parking brake lever (2). 5. Install the upper return spring (1) as shown. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Procedures > Page 5141 6. Flip the shoe assembly over to show the outboard side. 7. Install the lever pawl (1) onto the pivot located on the rear shoe (5). 8. Install the adjuster spring (2) between the front shoe (3) and the lever pawl (1). 9. Install the pre-assembled brake shoe assembly (3) through the opening between the wheel cylinder (1) and support plate hub and bearing. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Procedures > Page 5142 10. Insert the upper tips of the brake shoes into the grooves of the wheel cylinder (1) pistons. 11. Position the bottom of the front shoe against the anchor pin (5). 12. Install a shoe hold-down pin from the rear, through the support plate and the front shoe. 13. Compress and install the hold-down spring (2) retaining the front shoe to the support plate. 14. Compress the parking brake cable return spring, then carefully install the cable onto the parking brake lever. Release the spring guiding it beneath the retaining tab on the lever. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Procedures > Page 5143 15. Position the bottom of the rear shoe against the anchor pin (5). 16. Install a shoe hold-down pin from the rear, through the support plate and the rear shoe. 17. Compress and install the hold-down spring (4) retaining the rear shoe to the support plate. 18. Install the lower shoe spring (3). 19. Adjust the brake shoes to the drum diameter using a brake shoe gauge. 20. Install the brake drum (4). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Procedures > Page 5144 21. Install tire and wheel assembly (1). Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 22. Slowly rotate both rear wheels and verify that the brake drums lightly drag on the shoes. Further adjustments may be done using the adjustment procedure as necessary. 23. Lower the vehicle. 24. Road test vehicle stopping in both forward and reverse directions. The automatic-adjuster will continue to adjust brakes as necessary during road test. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Procedures Wheel Cylinder: Procedures INSPECTION With the brake drum removed, inspect the wheel cylinder boots for evidence of a brake fluid leak. Visually check the boots for cuts, tears, or heat cracks. If any of these conditions exist, the wheel cylinders must be replaced. If a wheel cylinder is leaking and the brake lining material is saturated with brake fluid, the brake shoes must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Procedures > Page 5149 Wheel Cylinder: Removal and Replacement Removal REMOVAL NOTE: Refer to Warnings and Cautions. 1. Using a brake pedal holder, depress the brake pedal past its first one inch of travel and hold it in this position. This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir. 2. Raise and support the vehicle. 3. Remove the wheel mounting nuts (3), then the tire and wheel assembly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Procedures > Page 5150 4. Access and remove the drum brake shoes (6) from the support plate (2). 5. Disconnect the brake tube (2) at the wheel cylinder. 6. Remove the wheel cylinder attaching screws (1). 7. Remove the wheel cylinder from the support plate. Installation INSTALLATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Procedures > Page 5151 1. Install the wheel cylinder onto the brake support plate. Install and tighten the mounting screws (1) to 13 Nm (115 in. lbs.). 2. Hand start the brake tube nut (2) into the wheel cylinder (1). Tighten the tube nut to 17 Nm (150 in. lbs.). NOTE: Inspect the brake shoes before installation. 3. Install the drum brake shoes (6) and drum. Adjust shoes as necessary. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Procedures > Page 5152 4. Install the tire and wheel assembly (1). Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 5. Slowly rotate the rear wheel and verify that the brake drum lightly drags on the shoes. 6. Lower the vehicle. 7. Remove the brake pedal holder. 8. Bleed the wheel cylinder as necessary. 9. Road test the vehicle to make sure the brakes operate correctly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding Brake Bleeding: Service and Repair Master Cylinder Bleeding MASTER CYLINDER BLEEDING NOTE: On vehicles without ABS this procedure is designed to be performed with the proportioning valves installed in the master cylinder. 1. Clamp the master cylinder in a vise with soft-jaw caps. 2. Master Cylinder without ABS - Attach the special tools for bleeding the master cylinder in the following fashion: a. Thread Bleeder Tube Adapter (1), Special Tool 8822-1, into the primary outlet port of the master cylinder without a proportioning valve. Tighten Adapter to 17 Nm (150 in. lbs.). b. Thread Bleeder Tube Adapter (2), Special Tool 8822-2, into the secondary outlet port of the master cylinder without a proportioning valve. Tighten Adapter to 17 Nm (150 in. lbs.). c. Thread Bleeder Tube Adapter (4), Special Tool 8822-1, into the proportioning valve in the lower secondary outlet port of the master cylinder. Tighten Adapter to 17 Nm (150 in. lbs.). d. Thread Bleeder Tube Adapter (5), Special Tool 8822-2, into the proportioning valve in the lower primary outlet port of the master cylinder. Tighten Adapter to 17 Nm (150 in. lbs.). e. Thread a Bleeder Tube (6), Special Tool 8358-1, into each Adapter. Tighten tube nuts to 17 Nm (150 in. lbs.). f. Install Bleeder Tubes Adapter (3), Special Tool 9705, in place of the fill cap as shown. g. Flex and place the open ends of the Bleeder Tubes into open hose tips on Adapter 9705. Be sure Bleeder Tubes are inserted into Adapter 9705 far enough not to come loose during bleed procedure. 3. Master Cylinder with ABS - Attach the special tools for bleeding the master cylinder in the following fashion: a. Thread Bleeder Tube Adapters (3), Special Tool 8822-2, into the primary and secondary outlet ports of the master cylinder. Tighten Adapters to 17 Nm (150 in. lbs.). b. Thread a Bleeder Tube (2), Special Tool 8358-1, into each Adapter. Tighten tube nuts to 17 Nm (150 in. lbs.). c. Flex each Bleeder Tube and place the open ends into the neck of the master cylinder reservoir. Position the open ends of the tubes into the reservoir so their outlets are below the surface of the brake fluid in the reservoir when filled. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 5158 NOTE: Make sure the ends of the Bleeder Tubes stay below the surface of the brake fluid in the reservoir at all times during the bleeding procedure. 4. Fill the brake fluid reservoir with fresh Mopar(R) Brake Fluid DOT 3 Motor Vehicle, or equivalent. 5. Using an appropriately sized wooden dowel as a pushrod, slowly press the pistons inward discharging brake fluid through the Bleeder Tubes, then release the pressure, allowing the pistons to return to the released position. Repeat this several times until all air bubbles are expelled from the master cylinder bore and Bleeder Tubes. 6. Remove the Bleeder Tubes and Adapters from the master cylinder and plug the master cylinder outlet ports. 7. Install the fill cap on the reservoir. 8. Remove the master cylinder from the vise. 9. Install the master cylinder on the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 5159 Brake Bleeding: Service and Repair Base Brake Bleeding BASE BRAKE BLEEDING NOTE: For bleeding the ABS hydraulic system, refer to Antilock Brake System Bleeding in the Antilock Brake System. CAUTION: Before removing the master cylinder cap, wipe it clean to prevent dirt and other foreign matter from dropping into the master cylinder reservoir. CAUTION: Use only Mopar(R) brake fluid or an equivalent from a fresh, tightly sealed container. Brake fluid must conform to DOT 3 specifications. NOTE: For bleeding of the Antilock Brake System, Refer to BRAKES - ABS STANDARD PROCEDURE. Do not pump the brake pedal at any time while having a bleeder screw open during the bleeding process. This will only increase the amount of air in the system and make additional bleeding necessary. Do not allow the master cylinder reservoir to run out of brake fluid while bleeding the system. An empty reservoir will allow additional air into the brake system. Check the fluid level frequently and add fluid as needed. The following wheel circuit sequence for bleeding the brake hydraulic system should be used to ensure adequate removal of all trapped air from the hydraulic system. - Left rear wheel - Right front wheel - Right rear wheel - Left front wheel MANUAL BLEEDING NOTE: To bleed the brakes manually, the aid of a helper will be required. 1. Attach a clear plastic hose (1) to the bleeder screw and feed the hose into a clear jar (2) containing enough fresh brake fluid to submerge the end of the hose. 2. Have a helper pump the brake pedal three or four times and hold it in the down position. 3. With the pedal in the down position, open the bleeder screw at least one full turn. 4. Once the brake pedal has dropped, close the bleeder screw. After the bleeder screw is closed, release the brake pedal. 5. Repeat the above steps until all trapped air is removed from that wheel circuit (usually four or five times). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 5160 6. Bleed the remaining wheel circuits in the same manner until all air is removed from the brake system. Monitor the fluid level in the master cylinder reservoir (2) to make sure it does not go dry. 7. Check and adjust brake fluid level to the FULL mark. 8. Check the brake pedal travel. If pedal travel is excessive or has not been improved, some air may still be trapped in the system. Re-bleed the brakes as necessary. 9. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct. PRESSURE BLEEDING NOTE: Follow pressure bleeder manufacturer's instructions for use of pressure bleeding equipment. 1. Attach Master Cylinder Cap (2), Special Tool 6921, in place of the filler cap on the master cylinder reservoir (3). 2. Attach Bleeder Tank (1), Special Tool C-3496-B, or an equivalent, to the Master Cylinder Cap 6921. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 5161 3. Attach a clear plastic hose (1) to the bleeder screw and feed the hose into a clear jar (2) containing enough fresh brake fluid to submerge the end of the hose. 4. Open the bleeder screw at least one full turn or more to obtain a steady stream of brake fluid. 5. After approximately 120-240 ml (4-8 ounces) of fluid have been bled through the brake circuit and an air-free flow is maintained in the clear plastic hose and jar, close the bleeder screw. 6. Repeat this procedure at all the remaining bleeder screws. 7. Check and adjust brake fluid level to the FULL mark on the reservoir (2). 8. Check the brake pedal travel. If pedal travel is excessive or has not been improved, some air may still be trapped in the system. Re-bleed the brakes as necessary. 9. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 5162 Brake Bleeding: Service and Repair Antilock Brake System Bleeding ANTILOCK BRAKE SYSTEM BLEEDING The base brake's hydraulic system must be bled anytime air enters the hydraulic system. The ABS must always be bled anytime it is suspected that the HCU has ingested air. Brake systems with ABS must be bled as two independent braking systems. The non-ABS portion of the brake system with ABS is to be bled the same as any non-ABS system. The ABS portion of the brake system must be bled separately. Use the following procedure to properly bleed the brake hydraulic system including the ABS. NOTE: During the brake bleeding procedure, be sure the brake fluid level remains close to the FULL level in the master cylinder fluid reservoir. Check the fluid level periodically during the bleeding procedure and add Mopar(R) DOT 3 brake fluid as required. BLEEDING When bleeding the ABS system, the following bleeding sequence must be followed to insure complete and adequate bleeding. 1. Make sure all hydraulic fluid lines are installed and properly torqued. 2. Connect the scan tool to the diagnostics connector. The diagnostic connector is located under the lower steering column cover to the left of the steering column. 3. Using the scan tool, check to make sure the ABM does not have any fault codes stored. If it does, clear them. WARNING: When bleeding the brake system wear safety glasses. A clear bleed tube (1) must be attached to the bleeder screws and submerged in a clear container filled part way with clean brake fluid (2). Direct the flow of brake fluid away from yourself and the painted surfaces of the vehicle. Brake fluid at high pressure may come out of the bleeder screws when opened. NOTE: Pressure bleeding is recommended to bleed the base brake system to ensure all air is removed from system. Manual bleeding may also be used, but additional time is needed to remove all air from system. 4. Bleed the base brake system. 5. Using the scan tool, select ECU VIEW, followed by ABS MISCELLANEOUS FUNCTIONS to access bleeding. Follow the instructions displayed. When finished, disconnect the scan tool and proceed. 6. Bleed the base brake system a second time. Check brake fluid level in the reservoir periodically to prevent emptying, causing air to enter the hydraulic system. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 5163 7. Fill the master cylinder fluid reservoir (1) to the FULL level. 8. Test drive the vehicle to be sure the brakes are operating correctly and that the brake pedal does not feel spongy. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures Brake Caliper: Procedures Cleaning CLEANING WARNING: Dust and dirt accumulating on brake parts during normal use may contain asbestos fibers from production or aftermarket brake linings. Breathing excessive concentrations of asbestos fibers can cause serious bodily harm. Exercise care when servicing brake parts. Do not sand or grind brake lining unless equipment used is designed to contain the dust residue. Do not clean brake parts with compressed air or by dry brushing. Cleaning should be done by dampening the brake components with a fine mist of water, then wiping the brake components clean with a dampened cloth. Dispose of cloth and all residue containing asbestos fibers in an impermeable container with the appropriate label. Follow practices prescribed by the Occupational Safety And Health Administration (OSHA) and the Environmental Protection Agency (EPA) for the handling, processing, and disposing of dust or debris that may contain asbestos fibers. To clean or flush the internal passages of the brake caliper, use fresh brake fluid or Mopar(R) Non-Chlorinated Brake Parts Cleaner. Never use gasoline, kerosene, alcohol, oil, transmission fluid or any fluid containing mineral oil to clean the caliper. These fluids will damage rubber cups and seals. Inspection INSPECTION Inspect the disc brake caliper for the following: - Brake fluid leaks in and around piston boot area - Ruptures, brittleness or damage to the piston dust boot If caliper fails inspection, disassemble and recondition caliper, replacing the seals and dust boots. Cleaning CLEANING WARNING: Dust and dirt accumulating on brake parts during normal use may contain asbestos fibers from production or aftermarket brake linings. Breathing excessive concentrations of asbestos fibers can cause serious bodily harm. Exercise care when servicing brake parts. Do not sand or grind brake lining unless equipment used is designed to contain the dust residue. Do not clean brake parts with compressed air or by dry brushing. Cleaning should be done by dampening the brake components with a fine mist of water, then wiping the brake components clean with a dampened cloth. Dispose of cloth and all residue containing asbestos fibers in an impermeable container with the appropriate label. Follow practices prescribed by the Occupational Safety And Health Administration (OSHA) and the Environmental Protection Agency (EPA) for the handling, processing, and disposing of dust or debris that may contain asbestos fibers. To clean or flush the internal passages of the brake caliper, use fresh brake fluid or Mopar(R) Non-Chlorinated Brake Parts Cleaner. Never use gasoline, kerosene, alcohol, oil, transmission fluid or any fluid containing mineral oil to clean the caliper. These fluids will damage rubber cups and seals. Inspection INSPECTION Inspect the disc brake caliper for the following: - Brake fluid leaks in and around boot area and inboard lining - Ruptures, brittleness or damage to the piston dust boot - Damaged, dry or brittle guide pin dust boots If caliper fails inspection, disassemble and recondition caliper, replacing the seals and dust boots. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5168 Brake Caliper: Removal and Replacement Removal REMOVAL NOTE: Refer to Warnings and Cautions. 1. Using a brake pedal holding tool as shown, depress the brake pedal past its first one inch (25 mm) of travel and hold it in this position. This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir when the lines are opened. 2. Raise and support the vehicle. 3. Remove the wheel mounting nuts (3), then the tire and wheel assembly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5169 4. Remove the banjo bolt (4) connecting the brake flex hose (2) to the brake caliper (5). There are two washers (3) that will come off with the banjo bolt. Discard the washers. NOTE: When removing the caliper guide pin bolts (2, 3) note that one (upper) has a special sleeve on the end. It is important that this bolt be installed in the upper mounting hole when the caliper is installed. 5. Remove the two brake caliper guide pin bolts (2, 3). 6. Slide the disc brake caliper (4) from the disc brake adapter bracket (1) and brake pads and remove. Installation INSTALLATION 1. Completely retract the caliper piston back into the bore of the caliper. Use a C-clamp to retract the piston. Place a wood block over the piston before installing the C-clamp to avoid damaging the piston. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5170 CAUTION: Use care when installing the caliper (4) onto the adapter bracket (1) to avoid damaging the guide pin boots. 2. Install the disc brake caliper over the brake pads on the brake caliper adapter bracket. NOTE: When installing the caliper guide pin bolts (2, 3) make sure that the one that has a special sleeve on the end is installed in the upper mounting hole. 3. Align the caliper guide pin bolt holes with the adapter bracket. Install the upper (with special sleeve) (2) and lower (3) caliper guide pin bolts. Tighten the guide pin bolts to 43 Nm (32 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5171 ERROR: undefined OFFENDING COMMAND: f‘~ STACK: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5172 Brake Caliper: Overhaul Disassembly DISASSEMBLY NOTE: Before disassembling the brake caliper, remove it from the vehicle. NOTE: Before disassembling the brake caliper, clean and inspect it. WARNING: Under no condition should high pressure air ever be used to remove a piston from a caliper bore. Personal injury could result from such a practice. CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will cause bore distortion. 1. Mount the caliper in a vise equipped with protective jaws. WARNING: Do not place face or hands near caliper and piston if using compressed air pressure to remove piston. Do not use high pressure. 2. Place a wooden block (1) in the caliper as shown. 3. If necessary, apply low pressure compressed air to the caliper fluid inlet in short spurts to force the piston out. 4. Remove the piston from the caliper. 5. Remove the dust boot from the piston and discard it. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5173 CAUTION: Do not use a screw driver or other metal tool for seal removal. Using such tools can scratch the bore or leave burrs on the seal groove edges. 6. Using a soft tool such as a plastic trim stick (1), work the piston seal (2) out of its groove in caliper piston bore. Discard the used seal. 7. Clean the piston bore and drilled passage ways with alcohol or a suitable solvent. Wipe it dry using only a lint-free cloth. 8. Inspect both the piston and bore for scoring or pitting. Bores that show light scratches or corrosion can usually be cleared of the light scratches or corrosion using crocus cloth. Assembly ASSEMBLY NOTE: Always have clean hands when assembling a brake caliper. NOTE: Always use fresh, clean brake fluid when assembling a brake caliper. NOTE: Never use an old piston seal. 1. Dip the NEW piston seal in clean brake fluid and install it in the groove (2) of the caliper bore. The seal (1) should be started at one area of the groove and gently worked around into the groove using only your clean fingers to seat it. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5174 2. Coat the NEW piston with clean brake fluid. 3. Coat the NEW piston boot with clean brake fluid leaving a generous amount inside the boot. 4. Position the dust boot over the lower section of the piston. 5. Extend the dust boot below the bottom of the piston and guide the lip seal into the groove in the caliper piston bore. CAUTION: Force applied to the piston (1) to seat it in the bore must be applied uniformly to avoid cocking and binding of the piston. 6. Install the piston (1) into the bore, carefully pushing it past the piston seal using hand pressure. Push the piston in until it bottoms in the caliper bore and the dust boot lip seal falls into the groove near the top of the piston. 7. Install the caliper on the vehicle and bleed the brakes as necessary. Disassembly DISASSEMBLY NOTE: Before disassembling the brake caliper, remove it from the vehicle. NOTE: Before disassembling the brake caliper, clean and inspect it. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5175 1. With finger tip, trace around the outside perimeter of the piston dust boot to find the ends of the boot snap-ring. 2. Using a small screwdriver (2) or like tool, carefully remove the boot snap-ring (1) making sure not to damage the dust boot, piston or piston bore. 3. Carefully pull the piston dust boot away from the caliper boot groove. WARNING: Under no condition should high pressure air ever be used to remove a piston from a caliper bore. Personal injury could result from such a practice. CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will cause bore distortion. 4. Mount the caliper in a vise equipped with protective jaws. WARNING: Do not place face or hands near caliper and piston if using compressed air pressure to remove piston. Do not use high pressure. 5. Place a wooden block (2) in the caliper as shown. 6. As necessary, apply low pressure compressed air to the caliper fluid inlet in short spurts to force the piston (1) out. 7. Remove the piston (with dust boot) from the caliper. 8. Remove the dust boot from the piston and discard it. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5176 CAUTION: Do not use a screw driver or other metal tool for seal removal. Using such tools can scratch the bore or leave burrs on the seal groove edges. 9. Using a soft tool such as a plastic trim stick (2), work the piston seal (1) out of its groove (3) in the caliper piston bore. Discard the used seal. 10. Clean the piston bore and drilled passage ways with alcohol or a suitable solvent. Wipe it dry using only a lint-free cloth. 11. Inspect both the piston and bore for scoring or pitting. Bores that show light scratches or corrosion can usually be cleared of the light scratches or corrosion using crocus cloth. Assembly ASSEMBLY NOTE: Always have clean hands when assembling a brake caliper. NOTE: Always use fresh, clean brake fluid when assembling a brake caliper. NOTE: Never use an old piston seal. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5177 1. Dip the NEW piston seal in clean brake fluid and install it in the groove (2) of the caliper piston bore. The seal (1) should be started at one area of the groove and gently worked around into the groove using only clean finger tips to seat it. 2. Coat the NEW piston dust boot (1) with clean brake fluid leaving a generous amount inside the boot. 3. Position the dust boot over the top of the piston (2) and into the piston groove. Make sure the side of the dust boot with the outer lip (3) for the boot snap-ring is positioned upward as shown. 4. Coat the piston with clean brake fluid. CAUTION: Force applied to the piston to seat it in the bore must be applied uniformly to avoid cocking and binding of the piston. 5. Insert the piston into the caliper bore, carefully pushing it past the piston seal using hand pressure. Push the piston in until it bottoms in the caliper bore. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5178 6. With finger tips, seat the dust boot lip (1) into the boot groove in the caliper bore. Trace around the outside perimeter of the dust boot with a finger tip making sure the lip is properly seated in the groove and not much air is trapped behind the boot. 7. Position one end of the boot snap-ring (1) inside the boot outer lip (2), then making a circular motion, walk the snap-ring around the boot lip, completely installing and seating it. 8. Inspect whether the two ends of the boot snap-ring are not overlapping one another. If they are, push the snap ring and dust boot further into groove removing any overlap of the snap-ring. 9. Install the caliper on the vehicle and bleed the brakes as necessary. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Brake Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 5183 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Page 5184 Brake Fluid: Specifications BRAKE FLUID The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar(R) Brake Fluid DOT 3 Motor Vehicle or equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum-based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Page 5185 Brake Fluid: Testing and Inspection BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swelling indicates the presence of petroleum in the brake fluid. To test for contamination, put a small amount of drained brake fluid in clear glass jar. If the fluid separates into layers, there is mineral oil or other fluid contamination of the brake fluid. If the brake fluid is contaminated, drain and thoroughly flush the brake system. Replace all the rubber parts or components containing rubber coming into contact with the brake fluid including: the master cylinder and reservoir; proportioning valves (non-ABS); caliper seals; wheel cylinder seals; ABS hydraulic control unit; and all hydraulic fluid hoses. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Page 5186 Brake Fluid: Service and Repair BRAKE FLUID LEVEL CHECKING NOTE: Brake fluid level should be checked a minimum of twice a year. Master cylinder reservoirs (2) are marked, FULL and ADD, indicating the allowable brake fluid level range in the master cylinder fluid reservoir. CAUTION: Use only Mopar(R) Brake Fluid DOT 3 Motor Vehicle or equivalent from a tightly sealed container. Do not use petroleum-based fluid because seal damage in the brake system will result. NOTE: Although there is a range, the preferred level is FULL. 1. Remove the cap (1). 2. Adjust the brake fluid level to the FULL mark listed on the side of the master cylinder fluid reservoir (2) as necessary. Do not overfill the system. 3. Install the cap (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations Brake Fluid Level Sensor/Switch: Locations Component ID: 283 Component : SENSOR-BRAKE FLUID LEVEL Connector: Name : SENSOR-BRAKE FLUID LEVEL Color : BLACK # of pins : 2 Pin Description Circuit 1 BRAKE FLUID LEVEL SWITCH SENSE B20 20DG/RD 2 GROUND Z925 20BK/YL Component Location - 6 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 5190 Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 5191 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 5192 Brake Fluid Level Sensor/Switch: Diagrams Component ID: 283 Component : SENSOR-BRAKE FLUID LEVEL Connector: Name : SENSOR-BRAKE FLUID LEVEL Color : BLACK # of pins : 2 Pin Description Circuit 1 BRAKE FLUID LEVEL SWITCH SENSE B20 20DG/RD 2 GROUND Z925 20BK/YL Component Location - 6 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 5193 Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 5194 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 5195 Brake Fluid Level Sensor/Switch: Description and Operation DESCRIPTION The brake fluid level switch (2) is mounted through the center of the fluid reservoir (1). The switch can be serviced separately from the master cylinder fluid reservoir. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Service and Repair > Removal Brake Fluid Level Sensor/Switch: Service and Repair Removal REMOVAL NOTE: Refer to Warnings and Cautions. 1. Remove the wiring harness connector (1) from the brake fluid level switch (2) in the master cylinder brake fluid reservoir. 2. Push together the retaining tabs (1) holding the brake fluid level switch in place in the brake fluid reservoir (2). 3. Pull the brake fluid level switch out the right side of the reservoir. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Service and Repair > Removal > Page 5198 Brake Fluid Level Sensor/Switch: Service and Repair Installation INSTALLATION 1. Align the brake fluid level switch with its mounting hole on the right side of the master cylinder brake fluid reservoir. Push the switch into the fluid reservoir until the switch retaining tabs (1) are expanded on the opposite side of the reservoir (2), locking it in place. 2. Connect the wiring harness connector (1) to the switch (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Description and Operation Brake Hose/Line: Description and Operation DESCRIPTION The brake tubes are steel with a corrosion-resistant nylon coating applied to the external surfaces. The flex hoses used at each wheel brake are made of reinforced rubber with fittings at each end. The fitting at each front brake caliper is the banjo-type and requires a special banjo bolt and copper washers. The fitting at each rear brake caliper is a screw-in type fitting. Rear drum brake vehicles use a standard tube nut fitting at each wheel cylinder. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Description and Operation > Page 5202 Brake Hose/Line: Testing and Inspection INSPECTION Brake tubing should be inspected periodically for evidence of physical damage or contact with moving or hot components. Flexible rubber hose is used at both the front and rear wheel brakes. Inspection of the flexible brake hoses should be performed whenever the brake system is serviced and every 12,000 km (7,500 miles) or 12 months, whichever comes first. Inspect hydraulic brake hoses for surface cracking, scuffing, or worn spots. If the fabric casing of the hose becomes exposed due to cracks or abrasions in the hose cover, the hose should be replaced immediately. Eventual deterioration of the hose can take place with possible burst failure. Faulty installation can cause twisting, resulting in wheel, tire, or chassis interference. NOTE: This vehicle is equipped with more than one size (diameter) brake tube depending on location on the vehicle. If a brake tube must be replaced, always use the same size brake tubing as that being replaced. Never use under-size brake tubing. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Description Brake Proportioning/Combination Valve: Description and Operation Description DESCRIPTION NOTE: Only vehicles without antilock brakes have proportioning valves. Vehicles with antilock brakes have Electronic Variable Brake Proportioning (EVBP) that is built into the Integrated Control Unit (ICU). On the non-antilock master cylinder (1), two screw-in proportioning valves (2, 3) are screwed directly into the rear brake outlet ports. The chassis brake tubes leading to the rear brakes attach to the outlets of the proportioning valves. One proportioning valve controls each rear brake. The proportioning valves are not identical and cannot be interchanged. The proportioning valve that threads into the primary port (3) has M10 x 1 threads going into the master cylinder (1). The proportioning valve that threads into the secondary port (2) has M12 x 1 threads going into the master cylinder (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Description > Page 5207 Brake Proportioning/Combination Valve: Description and Operation Operation OPERATION Proportioning valves balance front to rear braking by controlling the brake fluid hydraulic pressure to the rear brakes above a preset level (split point). Under light pedal application, the proportioning valve allows normal fluid flow to the rear brakes. Under higher pedal effort, the valve reduces fluid pressure to the rear brakes. This helps prevent rear wheel skid tendencies. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Service and Repair > Removal Brake Proportioning/Combination Valve: Service and Repair Removal REMOVAL NOTE: Refer to Warnings and Cautions. 1. Using a brake pedal holder, depress the brake pedal past its first one inch (25 mm) of travel and hold it in this position. This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir. NOTE: To access the lower (left rear) proportioning valve, it may help to remove the air cleaner cover and hose to the throttle body. 2. Disconnect the brake tube (1 or 2) from the proportioning valve requiring removal. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Service and Repair > Removal > Page 5210 3. Unscrew the proportioning valve (2 or 3) from the master cylinder (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Service and Repair > Removal > Page 5211 Brake Proportioning/Combination Valve: Service and Repair Installation INSTALLATION 1. Install the proportioning valve (2 or 3) in its master cylinder (1) port. Tighten the proportioning valve to 30 Nm (22 ft. lbs.). 2. Install the correct brake tube (1 or 2) to the proportioning valve. Tighten the tube nut to 17 Nm (150 in. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Service and Repair > Removal > Page 5212 3. Remove the brake pedal holder. 4. Bleed the affected brake line(s). 5. Road test the vehicle to ensure proper operation of the brakes. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > Hydraulic Control Unit (HCU) Hydraulic Control Assembly - Antilock Brakes: Description and Operation Hydraulic Control Unit (HCU) DESCRIPTION The Hydraulic Control Unit (HCU) is mounted to the Antilock Brake Module (ABM) as part of the Integrated Control Unit (ICU). The HCU controls the flow of brake fluid to the brakes using a series of valves and accumulators. A pump/motor is mounted on the HCU to supply build pressure to the brakes during an ABS stop. VALVES AND SOLENOIDS The valve block contains four inlet valves and four outlet solenoid valves. The inlet valves are spring-loaded in the open position and the outlet valves are spring-loaded in the closed position during normal braking. The fluid is allowed to flow from the master cylinder to the wheel brakes. During an ABS stop, these valves cycle to maintain the proper slip ratio for each wheel. The inlet valve closes preventing further pressure increase and the outlet valve opens to provide a path from the wheel brake to the HCU accumulators and pump/motor. This releases (decays) pressure from the wheel brake, thus releasing the wheel from excessive slippage. Once the wheel is no longer slipping, the outlet valve is closed and the inlet valve is opened to reapply (build) pressure. If the ABS includes the traction control feature, there are four other valves in the HCU. Two Traction Control (TC) valves, mounted in the HCU valve block, are normally in the open position and close only when the traction control is applied. There are also two shuttle valves which control pressure return to the master cylinder under ABS and traction control conditions. These TC valves are used to isolate the rear (non-driving) wheels of the vehicle from the hydraulic pressure that the HCU pump/motor is sending to the front (driving) wheels when traction control is being applied. The rear brakes need to be isolated from the master cylinder when traction control is being applied so the rear wheels do not drag. BRAKE FLUID ACCUMULATORS There are two fluid accumulators in the HCU: one for the primary hydraulic circuit, and one for the secondary hydraulic circuit. Each hydraulic circuit uses a 3 cc accumulator. The fluid accumulators temporarily store brake fluid that is removed from the wheel brakes during an ABS cycle. This stored fluid is used by the pump/motor to provide build pressure for the brake hydraulic system. When the antilock stop is complete, the accumulators are drained by the pump/motor. There are two noise dampening chambers in the HCU on this vehicle equipped with traction control. PUMP/MOTOR There are two pump assemblies in the HCU: one for the primary hydraulic circuit, and one for the secondary hydraulic circuit. Both pumps are driven by a common electric motor. This DC-type motor is integral to the HCU and is controlled by the ABM. The pump/motor provides the extra amount of brake fluid needed during antilock braking. Brake fluid is released to the accumulators when the outlet valve is opened during an antilock stop. The pump mechanism consists of two opposing pistons operated by an eccentric camshaft. In operation, these pistons are used to purge fluid from the accumulators back into the master cylinder circuits. When the antilock stop is complete, the pump/motor drains the accumulators. The pump motor is also used to build pressure when the system goes into Electronic Stability Program (ESP(R)) and traction control mode. The ABM may turn on the pump/motor when an antilock stop is detected. The pump/motor continues to run during the antilock stop and is turned off after the stop is complete. Under some conditions, the pump/motor runs to drain the accumulators during the next drive-off. The pump/motor is not a serviceable item; if it requires replacement, the HCU must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > Hydraulic Control Unit (HCU) > Page 5217 Hydraulic Control Assembly - Antilock Brakes: Description and Operation Integrated Control Unit (ICU) Description DESCRIPTION The Hydraulic Control Unit (HCU) (2) and the Antilock Brake Module (ABM) (1) used with this antilock brake system are combined (integrated) into one unit, which is called the Integrated Control Unit (ICU). The ICU (1) is located in the engine compartment, mounted to the right side body frame rail near the strut tower. Two different ICU's are used on this vehicle depending on whether or not the vehicle is equipped with traction control and Electronic Stability Program (ESP(R)). The HCU on a vehicle equipped with traction control or ESP(R) has a valve block that is approximately one inch longer than a HCU on a vehicle that is equipped with ABS only. The ABS-only ICU consists of the following components: the ABM, eight (build/decay) solenoid valves (four inlet valves and four outlet valves), valve Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > Hydraulic Control Unit (HCU) > Page 5218 block, fluid accumulators, a pump, and an electric motor. The ABS with ESP(R) and All-Speed Traction Control ICU consists of the following components: the ABM, 12 (build/decay) solenoid valves, two traction control solenoid valves, two hydraulic shuttle valves, valve block, fluid accumulators, a pump, and an electric pump/motor. The replaceable components of the ICU are the HCU and the ABM. No attempt should be made to service any components of the HCU or ABM. For additional information on the ABM, Refer to ANTILOCK BRAKE MODULE - DESCRIPTION). For additional information on the HCU, Refer to BRAKES ABS/HYDRAULIC/MECHANICAL/HCU (HYDRAULIC CONTROL UNIT) - DESCRIPTION). Operation OPERATION For information of the ICU, refer to these individual components of the ICU: - ANTILOCK BRAKE MODULE (ABM) Refer to ANTILOCK BRAKE MODULE DESCRIPTION - HYDRAULIC CONTROL UNIT (HCU) Refer to HYDRAULIC CONTROL UNIT - DESCRIPTION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Replacement Hydraulic Control Assembly - Antilock Brakes: Removal and Replacement Removal REMOVAL To remove the HCU, the ICU must be removed and disassembled. Installation INSTALLATION To install the HCU, assemble and install the ICU. Removal INTEGRATED CONTROL UNIT - GAS ENGINE NOTE: Refer to Warnings and Cautions. 1. Disconnect and isolate battery negative cable from battery post. 2. Using a brake pedal holding tool as shown, depress the brake pedal past its first 25 mm (1 inch) of travel and hold it in this position. This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir while the lines are disconnected. 3. Remove the engine appearance cover. 4. Loosen lower and upper mounting nuts, then remove the exhaust heat shield from the dash panel. 5. Pull the brake tube bundle routing clips (with tubes) loose from studs on the dash panel. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 5221 6. Remove the primary (4) and secondary (1) brake tubes (from master cylinder) at the hydraulic control unit (7). 7. Remove the remaining brake tubes (2, 3, 5, 6) at the hydraulic control unit (7). 8. Remove the screw (1) fastening the power steering pressure hose routing clamp (2) to the exhaust manifold. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 5222 NOTE: Use this figure in the following step to release the ABM harness connector cover. It shows the location of the release tabs. 9. Disconnect the ABM harness connector from the Antilock Brake Module (ABM). To do so: a. Depress the tabs on each side of the connector cover, then b. Pull outward and upward on the lower half of the cover until it locks into position pointing straight outward (2). The connector can then be pulled straight outward off the ABM (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 5223 10. Loosen, but do not remove, the two mounting screws (2) attaching the ICU (1) mounting bracket to the body. 11. Lift the ICU and mounting bracket (1) off the mounting screws (2). 12. Move the brake tubes around as necessary without bending them and remove the ICU with bracket through the opening between the A/C lines and the exhaust manifold. 13. To separate the ABM from the HCU, Refer to BRAKES/HYDRAULIC/MECHANICAL/ICU (INTEGRATED CONTROL UNIT) DISASSEMBLY. Installation INTEGRATED CONTROL UNIT - GAS ENGINE 1. Install the ICU with bracket (1) through the opening between the A/C lines and the exhaust manifold using the opposite of how it was removed. 2. Place the mounting bracket for the ICU (1) over the mounting screws (2) and hang the assembly in place. Tighten the two mounting screws (2) to 23 Nm (17 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 5224 CAUTION: Before installing the ABM harness connector on the ABM, be sure the seal is properly installed in the connector. 3. Insert the ABM wiring harness connector (2) into the socket of the ABM (1) and close the cover, locking the connector in place. 4. Install the four chassis brake tubes (2, 3, 5, 6) brake tubes at the ICU hydraulic control unit (7). Tighten the tube nuts to 17 Nm (150 in. lbs.). 5. Install the primary (4) and secondary (1) brake tubes at the ICU hydraulic control unit (7). Tighten the tube nuts to 17 Nm (150 in. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 5225 6. Position the power steering pressure hose routing clamp (2) on the exhaust manifold and install the mounting screw (1). Tighten the mounting screw to 9 Nm (80 in. lbs.). 7. Push the brake tube bundle routing clips (with tubes) onto the studs on the dash panel. 8. Install the heat shield on the dash panel and tighten the lower and upper mounting nuts. 9. Remove the brake pedal holding tool. 10. Install the engine appearance cover. 11. Connect the battery negative cable to the battery post. It is important that this be performed properly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 5226 12. Hook up the scan tool to initialize the ABM and perform the following: a. Clear any faults. b. Fill the master cylinder to the proper fill level and bleed the base and ABS hydraulic systems. c. Check for leaks. d. Perform the ABS Verification Test and road test the vehicle. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 5227 Hydraulic Control Assembly - Antilock Brakes: Overhaul Disassembly DISASSEMBLY 1. If the mounting bracket (3) needs to be removed from the ICU, remove the single mounting bolt (2), then slide the ICU's mounting pins out of the grommets in the bracket and remove the bracket. 2. Remove the mounting pins from the ICU. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 5228 3. If not equipped with ESP(R) or traction control, remove the three screws (1) attaching the ABM (2) to the HCU. 4. If equipped with ESP(R) or traction control, remove the four screws (1) attaching the ABM (2) to the HCU. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 5229 5. Separate the ABM (1) from the HCU (2). Assembly ASSEMBLY 1. Clean any debris off the mating surfaces of the HCU and ABM. CAUTION: When installing new O-rings or solenoid valve stem seals, do not use any type of lubricant. 2. If the seals (1) on the solenoid valve stems (2) are not new, replace them all. Each of the solenoid valve stem seals must be new to keep out moisture and debris; do not reuse solenoid valve stem seals. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 5230 3. Replace the pump/motor connector O-ring (1) if it is not new. Be sure the O-ring is properly seated in the mounting groove (2). 4. Align components and install the ABM (1) on the HCU (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 5231 5. If not equipped with ESP(R) or traction control, install the three screws (1) attaching the ABM (2) to the HCU. Tighten the mounting screws to 2 Nm (17 in. lbs.). 6. If equipped with ESP(R) or traction control, install the four screws (1) attaching the ABM (2) to the HCU. Tighten the mounting screws to 2 Nm (17 in. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 5232 7. If necessary, install the mounting pins (1) in the ICU (2) and tighten to 11 Nm (97 in. lbs.). 8. If the mounting bracket (3) needs to be installed on the ICU (1), install the mounting pins in the ICU as necessary and tighten to 11 Nm (97 in. lbs.). Insert the mounting pins into the grommets mounted in the bracket, then install the single mounting bolt (2). Tighten the mounting bolt to 11 Nm (97 in. lbs.). 9. Install the ICU in the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Description Brake Master Cylinder: Description and Operation Description DESCRIPTION The master cylinder used on this vehicle is a Plunger II design supplied by Continental Teves. The bore diameter for all applications is 20.6 mm (0.812 in.). The non-ABS master cylinder (3) is a four-outlet design (one for each wheel brake). There are two ports at each piston. One feeds a front wheel brake while the other feeds the opposite side rear wheel brake. The rear wheel brake ports are drilled and threaded to accept screw-in proportioning valves. Both valves are threaded into the bottom of the master cylinder housing. All ABS master cylinders (3) are a two-outlet design and the brake tubes from these primary and secondary outlet ports lead directly to the Integrated Control Unit (ICU) before going to each wheel brake. All master cylinders mount to the power brake booster in the same manner. The master cylinder body is an anodized aluminum casting. It has a machined bore to accept the master cylinder pistons and also has threaded ports with seats for hydraulic brake tube connections. The master cylinder has the brake fluid reservoir mounted on top of it which gravity feeds brake fluid to the master cylinder when it is required. On manual transmission model vehicles the brake fluid reservoir also feeds the clutch hydraulic circuit. The reservoir is made of see-through plastic and it houses the brake fluid level switch. A removable brake fluid level switch is mounted in the right side. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Description > Page 5237 Brake Master Cylinder: Description and Operation Operation OPERATION When the brake pedal is pressed, the master cylinder primary and secondary pistons apply brake pressure through the proportioning valves (on non-ABS vehicles) and chassis brake tubes to each brake assembly. The brake fluid reservoir supplies the brake hydraulic system with the necessary fluid to operate properly. The non-ABS master cylinder's primary outlet ports supply hydraulic pressure to the right front and left rear brakes while the secondary outlet ports supply hydraulic pressure to the left front and right rear brakes. ABS equipped master cylinder outlet ports supply hydraulic pressure to the ABS Integrated Control Unit (ICU) where it is distributed to the individual wheel brakes. The master cylinder reservoir cap diaphragm is slit to allow atmospheric pressure to equalize on both sides of the diaphragm. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures Brake Master Cylinder: Procedures MASTER CYLINDER BLEEDING NOTE: On vehicles without ABS this procedure is designed to be performed with the proportioning valves installed in the master cylinder. 1. Clamp the master cylinder in a vise with soft-jaw caps. 2. Master Cylinder without ABS - Attach the special tools for bleeding the master cylinder in the following fashion: a. Thread Bleeder Tube Adapter (1), Special Tool 8822-1, into the primary outlet port of the master cylinder without a proportioning valve. Tighten Adapter to 17 Nm (150 in. lbs.). b. Thread Bleeder Tube Adapter (2), Special Tool 8822-2, into the secondary outlet port of the master cylinder without a proportioning valve. Tighten Adapter to 17 Nm (150 in. lbs.). c. Thread Bleeder Tube Adapter (4), Special Tool 8822-1, into the proportioning valve in the lower secondary outlet port of the master cylinder. Tighten Adapter to 17 Nm (150 in. lbs.). d. Thread Bleeder Tube Adapter (5), Special Tool 8822-2, into the proportioning valve in the lower primary outlet port of the master cylinder. Tighten Adapter to 17 Nm (150 in. lbs.). e. Thread a Bleeder Tube (6), Special Tool 8358-1, into each Adapter. Tighten tube nuts to 17 Nm (150 in. lbs.). f. Install Bleeder Tubes Adapter (3), Special Tool 9705, in place of the fill cap as shown. g. Flex and place the open ends of the Bleeder Tubes into open hose tips on Adapter 9705. Be sure Bleeder Tubes are inserted into Adapter 9705 far enough not to come loose during bleed procedure. 3. Master Cylinder with ABS - Attach the special tools for bleeding the master cylinder in the following fashion: a. Thread Bleeder Tube Adapters (3), Special Tool 8822-2, into the primary and secondary outlet ports of the master cylinder. Tighten Adapters to 17 Nm (150 in. lbs.). b. Thread a Bleeder Tube (2), Special Tool 8358-1, into each Adapter. Tighten tube nuts to 17 Nm (150 in. lbs.). c. Flex each Bleeder Tube and place the open ends into the neck of the master cylinder reservoir. Position the open ends of the tubes into the reservoir so their outlets are below the surface of the brake fluid in the reservoir when filled. NOTE: Make sure the ends of the Bleeder Tubes stay below the surface of the brake fluid in the reservoir at all times during the bleeding procedure. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 5240 4. Fill the brake fluid reservoir with fresh Mopar(R) Brake Fluid DOT 3 Motor Vehicle, or equivalent. 5. Using an appropriately sized wooden dowel as a pushrod, slowly press the pistons inward discharging brake fluid through the Bleeder Tubes, then release the pressure, allowing the pistons to return to the released position. Repeat this several times until all air bubbles are expelled from the master cylinder bore and Bleeder Tubes. 6. Remove the Bleeder Tubes and Adapters from the master cylinder and plug the master cylinder outlet ports. 7. Install the fill cap on the reservoir. 8. Remove the master cylinder from the vise. 9. Install the master cylinder on the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 5241 Brake Master Cylinder: Removal and Replacement Master Cylinder - Right-Hand-Drive MASTER CYLINDER - RIGHT-HAND-DRIVE NOTE: Refer to Warnings and Cautions. CAUTION: The vacuum in the power brake booster must be pumped down before removing the master cylinder to prevent the booster from sucking in any contamination. This can be done by pumping the brake pedal while the engine is not running until a firm brake pedal is achieved. 1. With the engine not running, pump the brake pedal 4-5 strokes until the pedal feel is firm. 2. Disconnect the negative (ground) cable from the battery and isolate the cable. 3. Remove the engine appearance cover. 4. Disconnect the wiring harness connector (1) from the brake fluid level switch (2) in the master cylinder brake fluid reservoir. 5. If equipped with a manual transaxle, remove the clamp and slide the clutch actuator hose (2) off the reservoir port (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 5242 6. Disconnect the primary (1) and secondary (2) brake tubes at the master cylinder outlet ports. Install plugs at both of the open brake tube outlets on the master cylinder. 7. Clean the area around where the master cylinder (2) attaches to the power brake booster (1) using a suitable brake cleaner such as Mopar(R) Brake Parts Cleaner or an equivalent. 8. Remove the two nuts (3) attaching the master cylinder (2) to the power brake booster (1). 9. Slide the master cylinder straight out of the power brake booster, then lower it below the air conditioning lines and remove it from the engine compartment inboard of the air conditioning lines. Master Cylinder - With ABS MASTER CYLINDER - WITH ABS NOTE: Refer to Warnings and Cautions. CAUTION: The vacuum in the power brake booster must be pumped down before removing the master cylinder to prevent the booster from sucking in any contamination. This can be done by pumping the brake pedal while the engine is not running until a firm brake pedal is achieved. 1. With the engine not running, pump the brake pedal 4 - 5 strokes until the pedal feel is firm. 2. Disconnect the negative (ground) cable from the battery and isolate the cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 5243 3. Disconnect the wiring harness connector (1) from the brake fluid level switch (2) in the master cylinder brake fluid reservoir. 4. Disconnect the primary (1) and secondary (2) brake tubes at the master cylinder outlet ports. Install plugs at all of the open brake tube outlets on the master cylinder. 5. If equipped with a manual transaxle, remove the clamp and slide the clutch actuator hose (2) off the reservoir port (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 5244 6. Clean the area around where the master cylinder (2) attaches to the power brake booster (1) using a suitable brake cleaner such as Mopar(R) Brake Parts Cleaner or an equivalent. 7. Remove the two nuts (3) attaching the master cylinder (2) to the power brake booster (1). 8. Slide the master cylinder straight out of the power brake booster. Master Cylinder - Without ABS MASTER CYLINDER - WITHOUT ABS NOTE: Refer to Warnings and Cautions. CAUTION: The vacuum in the power brake booster must be pumped down before removing the master cylinder to prevent the booster from sucking in any contamination. This can be done by pumping the brake pedal while the engine is not running until a firm brake pedal is achieved. 1. With the engine not running, pump the brake pedal 4 - 5 strokes until the pedal feel is firm. 2. Disconnect the negative (ground) cable from the battery and isolate the cable. 3. Remove the wiring harness connector (1) from the brake fluid level switch (2) in the master cylinder brake fluid reservoir. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 5245 4. Disconnect the two front brake tubes (1, 2) from the master cylinder. Install plugs at the open brake tube outlets on the master cylinder. 5. Disconnect the two rear brake tubes (1, 2) from the proportioning valves on the master cylinder (3). Install plugs at the open brake tube outlets on the proportioning valves. 6. If equipped with a manual transaxle, remove the clamp and slide the clutch actuator hose (2) off the reservoir port (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 5246 7. Clean the area around where the master cylinder (2) attaches to the power brake booster (1) using a suitable brake cleaner such as Mopar(R) Brake Parts Cleaner or an equivalent. 8. Remove the two nuts (3) attaching the master cylinder (2) to the power brake booster (1). 9. Slide the master cylinder straight out of the power brake booster. 10. To remove the proportioning valves, unthread each from the master cylinder. Master Cylinder - Right-Hand-Drive MASTER CYLINDER - RIGHT-HAND-DRIVE NOTE: The master cylinder must be bled before installing it on the vehicle. 1. Bench bleed the master cylinder. 2. Wipe the face of the power brake booster clean where the vacuum seal on the rear of the master cylinder comes in contact when it's installed. Do not get any cleaner or debris inside the booster. CAUTION: When installing a master cylinder on the vehicle, a NEW vacuum seal (2) MUST be installed on the master cylinder mounting flange (1). 3. If the master cylinder does not have a new vacuum seal (2) on the mounting flange (1), remove it. Install a NEW vacuum seal on the master cylinder mounting flange making sure the seal fits squarely in its groove. CAUTION: If resistance is met during master cylinder insertion into power brake booster, the master cylinder push rod may not be lined up with the booster push rod. Remove the master cylinder, realign and insert it again. 4. Install the master cylinder into the engine compartment as follows: a. Starting on the inboard side of the air conditioning lines behind the engine, guide the master cylinder below the air conditioning lines, then up in front of the power brake booster. b. Line up the master cylinder mounting holes with the mounting studs on the power brake booster. Ensure the master cylinder piston push rod lines up with the booster push rod, then carefully slide the master cylinder into the power brake booster until it contacts the face of the booster. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 5247 5. Install two NEW master cylinder mounting nuts (3). Tighten each nut to 25 Nm (18 ft. lbs.). 6. Connect the primary (1) and secondary (2) brake tubes to the master cylinder outlet ports. Tighten the tube nuts to 17 Nm (150 in. lbs.). 7. If equipped with a manual transaxle and a new reservoir is being installed, using an appropriate cutting tool, cut the clutch actuator port at the center of the "V" groove (2) opening the hydraulic clutch port (1). Discard the severed plug (3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 5248 8. If equipped with a manual transaxle, slide the clutch actuator hose (2) onto the reservoir port (1). Install the hose clamp just past the upset bead on the port. 9. Connect the wiring harness connector (1) to the brake fluid level switch (2). 10. Install the engine appearance cover. 11. Connect the negative (ground) cable on the battery. 12. Fill the master cylinder reservoir to the proper level. WARNING: Be certain a firm brake pedal is achieved prior to attempting to operate the vehicle. If a firm brake pedal cannot be achieved, bleed the brake hydraulic system and check for leaks. 13. Road test the vehicle to ensure proper operation of the brakes. Master Cylinder - With ABS MASTER CYLINDER - WITH ABS NOTE: The master cylinder must be bled before installing it on the vehicle. 1. Bench bleed the master cylinder. 2. Wipe the face of the power brake booster clean where the vacuum seal on the rear of the master cylinder comes in contact when it's installed. Do not get any cleaner or debris inside the booster. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 5249 CAUTION: When installing a master cylinder on the vehicle, a NEW vacuum seal (2) MUST be installed on the master cylinder mounting flange (1). 3. If the master cylinder does not have a new vacuum seal (2) on the mounting flange (1), remove it. Install a NEW vacuum seal on the master cylinder mounting flange making sure the seal fits squarely in its groove. CAUTION: If resistance is met during master cylinder insertion into power brake booster, the master cylinder push rod may not be lined up with the booster push rod. Remove the master cylinder, realign and insert it again. 4. Line the master cylinder mounting holes up with the mounting studs on the power brake booster. Ensure the master cylinder piston push rod lines up with the booster push rod, then carefully slide the master cylinder into the power brake booster until it contacts the face of the booster. 5. Install two NEW master cylinder mounting nuts (3). Tighten each nut to 25 Nm (18 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 5250 6. If equipped with a manual transaxle and a new reservoir is being installed, using an appropriate cutting tool, cut the clutch actuator port at the center of the "V" groove (2) opening the hydraulic clutch port (1). Discard the severed plug (3). 7. If equipped with a manual transaxle, slide the clutch actuator hose (2) onto the reservoir port (1). Install the hose clamp just past the upset bead on the port. 8. Connect the primary (1) and secondary (2) brake tubes to the master cylinder outlet ports. Tighten the tube nuts to 17 Nm (150 in. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 5251 9. Connect the wiring harness connector (1) to the brake fluid level switch (2). WARNING: A reservoir blocker must be installed on the master cylinder brake fluid reservoir. Failure to install the reservoir blocker can result in fire in the event of an accident, resulting in serious or fatal injury. 10. If not present, a reservoir blocker (1) must be installed on the fluid reservoir (2). The blocker can be removed from the original reservoir by releasing the retaining tab (3) and opening the blocker. To install the blocker, encircle the reservoir neck with the blocker, close the blocker, snapping the retaining tab into place. Make sure the blocker is securely latched. 11. Connect the negative (ground) cable on the battery. 12. Fill the master cylinder reservoir to the proper level. WARNING: Be certain a firm brake pedal is achieved prior to attempting to operate the vehicle. If a firm brake pedal cannot be achieved, bleed the brake hydraulic system and check for leaks. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 5252 13. Road test the vehicle to ensure proper operation of the brakes. Master Cylinder - Without ABS MASTER CYLINDER - WITHOUT ABS NOTE: The proportioning valves are not identical and cannot be interchanged. The proportioning valve that threads into the primary port (3) has M10 x 1 threads going into the master cylinder (1). The proportioning valve that threads into the secondary port (2) has M12 x 1 threads going into the master cylinder (1). 1. If removed, install the proportioning valves (2, 3) in their master cylinder ports. Tighten the proportioning valves to 30 Nm (22 ft. lbs.). NOTE: The master cylinder must be bled before installing it on the vehicle. 2. Bench bleed the master cylinder. 3. Wipe the face of the power brake booster clean where the master cylinder seal comes in contact when it's installed. Do not get any cleaner or debris inside the booster. CAUTION: When installing a master cylinder on the vehicle, a NEW vacuum seal (2) MUST be installed on the master cylinder mounting flange (1). 4. If the master cylinder does not have a new vacuum seal (2) on the mounting flange (1), remove it. Install a NEW vacuum seal on the master cylinder mounting flange making sure the seal fits squarely in its groove. CAUTION: If resistance is met during master cylinder insertion into power brake booster, the master cylinder push rod may not be lined up with the booster push rod. Remove the master cylinder, realign and insert it again. 5. Line the master cylinder mounting holes up with the mounting studs on the power brake booster. Ensure the master cylinder piston push rod lines up with the booster push rod, then carefully slide the master cylinder into the power brake booster until it contacts the face of the booster. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 5253 6. Install two NEW master cylinder mounting nuts (3). Tighten each nut to 25 Nm (18 ft. lbs.). 7. If equipped with a manual transaxle and a new reservoir is being installed, using an appropriate cutting tool, cut the clutch actuator port at the center of the "V" groove (2) opening the hydraulic clutch port (1). Discard the severed plug (3). 8. If equipped with a manual transaxle, slide the clutch actuator hose (2) onto the reservoir port (1). Install the hose clamp just past the upset bead on the port. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 5254 9. Connect the two rear brake tubes (1, 2) to the proportioning valves on the master cylinder (3). Tighten the tube nuts to 17 Nm (150 in. lbs.). 10. Connect the two front brake tubes (1, 2) to the master cylinder. Tighten the tube nuts to 17 Nm (150 in. lbs.). 11. Connect the wiring harness connector (1) to the brake fluid level switch (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 5255 WARNING: A reservoir blocker must be installed on the master cylinder brake fluid reservoir. Failure to install the reservoir blocker can result in fire in the event of an accident, resulting in serious or fatal injury. 12. If not present, a reservoir blocker (1) must be installed on the fluid reservoir (2). The blocker can be removed from the original reservoir by releasing the retaining tab (3) and opening the blocker. To install the blocker, encircle the reservoir neck with the blocker, close the blocker, snapping the retaining tab into place. Make sure the blocker is securely latched. 13. Connect the negative (ground) cable on the battery. 14. Fill the master cylinder reservoir to the proper level. WARNING: Be certain a firm brake pedal is achieved prior to attempting to operate the vehicle. If a firm brake pedal cannot be achieved, bleed the brake hydraulic system and check for leaks. 15. Road test the vehicle to ensure proper operation of the brakes. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 5256 Brake Master Cylinder: Overhaul Disassembly DISASSEMBLY 1. Clean the master cylinder housing and brake fluid reservoir. Use only Mopar(R) Brake Parts Cleaner or equivalent. 2. Remove the brake fluid reservoir cap (1). Using a syringe or equivalent type tool, empty as much brake fluid as possible from the reservoir. CAUTION: When removing the fluid reservoir (1) from the master cylinder, do not attempt to pry it off using any type of tool. This can damage the fluid reservoir or master cylinder housing. 3. Remove the screw (3) fastening the fluid reservoir (1) to the master cylinder housing. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 5257 4. Pull the reservoir (1) straight up and remove it from the grommet seals in master cylinder housing (2). 5. If the reservoir is being replaced, remove the fluid level switch. Push together the retaining tabs (1) holding the brake fluid level switch in place in the brake fluid reservoir (2), then pull the brake fluid level switch out the opposite side of the reservoir. 6. Remove the vacuum seal (2) from the master cylinder mounting flange (1). Assembly Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 5258 ASSEMBLY 1. Install a NEW vacuum seal (2) on the master cylinder mounting flange (1) making sure the seal fits squarely in its groove. 2. If the reservoir is being replaced, align the brake fluid level switch with its mounting hole on the left side of the master cylinder brake fluid reservoir. Push the switch into the fluid reservoir until the switch retaining tabs (1) are expanded on the other side of the reservoir (2), locking it in place. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 5259 3. Lubricate the reservoir mounting area with fresh clean brake fluid. Place the reservoir (1) in position over the grommet seals in the master cylinder (2). Slide the reservoir into the grommet seals by firmly pressing down on the fluid reservoir. Once installed, make sure fluid reservoir is touching the top of both grommet seals. 4. Install the fluid reservoir mounting screw (3). Tighten the screw to 5.5 Nm (48 in. lbs.). 5. Thoroughly bleed the master cylinder before installing it. 6. Install the master cylinder. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Procedures Wheel Cylinder: Procedures INSPECTION With the brake drum removed, inspect the wheel cylinder boots for evidence of a brake fluid leak. Visually check the boots for cuts, tears, or heat cracks. If any of these conditions exist, the wheel cylinders must be replaced. If a wheel cylinder is leaking and the brake lining material is saturated with brake fluid, the brake shoes must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Procedures > Page 5264 Wheel Cylinder: Removal and Replacement Removal REMOVAL NOTE: Refer to Warnings and Cautions. 1. Using a brake pedal holder, depress the brake pedal past its first one inch of travel and hold it in this position. This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir. 2. Raise and support the vehicle. 3. Remove the wheel mounting nuts (3), then the tire and wheel assembly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Procedures > Page 5265 4. Access and remove the drum brake shoes (6) from the support plate (2). 5. Disconnect the brake tube (2) at the wheel cylinder. 6. Remove the wheel cylinder attaching screws (1). 7. Remove the wheel cylinder from the support plate. Installation INSTALLATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Procedures > Page 5266 1. Install the wheel cylinder onto the brake support plate. Install and tighten the mounting screws (1) to 13 Nm (115 in. lbs.). 2. Hand start the brake tube nut (2) into the wheel cylinder (1). Tighten the tube nut to 17 Nm (150 in. lbs.). NOTE: Inspect the brake shoes before installation. 3. Install the drum brake shoes (6) and drum. Adjust shoes as necessary. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Procedures > Page 5267 4. Install the tire and wheel assembly (1). Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 5. Slowly rotate the rear wheel and verify that the brake drum lightly drags on the shoes. 6. Lower the vehicle. 7. Remove the brake pedal holder. 8. Bleed the wheel cylinder as necessary. 9. Road test the vehicle to make sure the brakes operate correctly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal Parking Brake Cable: Service and Repair Removal REMOVAL NOTE: Refer to Warnings and Cautions. NOTE: The procedure below applies to either of the two rear parking brake cables. 1. Disconnect and isolate the battery negative cable from its post on the battery. 2. Block the tire and wheel assemblies so the vehicle does not move once the vehicle parking brake lever is released. 3. Remove the center console. 4. Release and lower the parking brake lever (5). 5. Loosen the adjusting nut on the lever's output cable taking tension off parking brake cables. 6. Remove the parking brake cables (3) from the parking brake cable equalizer (2). 7. Remove the rear seat cushion. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal > Page 5273 8. Fold the rear carpeting forward (1) to expose the parking brake cables (4) at the end of the rear floor. 9. Install the box end of a 1/2 inch (13 mm) wrench (2) over the retainer for either the right (3) or left (5) parking brake cable. Push the wrench onto the retainer until the retainer fingers are collapsed. From under the carpeting, grasp the parking brake cable housing and pull the cable straight out of the bracket attached to the floor. 10. Raise and support the vehicle. 11. Remove the wheel mounting nuts (3), then the rear tire and wheel assembly (1). 12. Access and remove the parking brake shoes. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal > Page 5274 13. Remove the hair pin (1) securing the parking brake cable (2) to the brake support plate (3). 14. Pull the parking brake cable from the support plate and hole in trailing link. 15. Remove the screw (4) securing the cable routing clamp (3) to the body (2). 16. Remove the nut (5) securing the cable routing clamp (3) to the fuel tank strap (7). 17. Remove the parking brake cable (1 - right cable, 9 - left cable) with sealing grommet (6) through the hole (8) in the floor pan of the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal > Page 5275 Parking Brake Cable: Service and Repair Installation INSTALLATION NOTE: The following procedure applies to either of the two rear parking brake cables. 1. From underneath, push the parking brake cable through the hole (8) in the floor pan of the vehicle making sure the cable sealing grommet (6) is installed in the floor pan as far as possible (without going all the way through) to ensure a good seal. 2. Position the cable routing clamp (3) over the stud on the fuel tank strap (7) and install the nut (5). 3. Position the cable routing clamp (3) and install the screw (4) securing the cable (1 - right cable, 9 - left cable) to the body (2). 4. Insert the parking brake cable through the hole in the trailing link and the support plate (3). 5. Install the hair pin (1) securing the parking brake cable (2) to the brake support plate (3). 6. Install the parking brake shoes (and check adjustment) and components removed to access them. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal > Page 5276 7. Install tire and wheel assembly (1). Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 8. Lower the vehicle. 9. Block the tire and wheel assemblies so the vehicle does not move with the vehicle parking brake lever released. 10. Ensure that the seal grommet on the cable installed from underneath is fully seated into the floor pan. 11. Route the parking brake cable under the carpeting, up to the parking brake cable retaining bracket (4) on the floor pan. Insert the parking brake cable (3) through the retaining bracket. Push the cable in until the locking fingers on the cable retainer lock the cable into place. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal > Page 5277 CAUTION: A NEW parking brake cable equalizer (2) must be installed when servicing the parking brake cables or lever. The equalizer has an integrated bent nail tensioner that needs to be stretched upon installation placing the correct tension on the cables. 12. Remove and install a NEW parking brake cable equalizer (2) on the parking brake lever output cable. 13. Install the rear parking brake cables (3) into the equalizer (2) on the parking brake lever output cable. 14. Ensure that the parking brake cables are correctly installed on the equalizer and aligned with the cable track on the parking brake lever. NOTE: Actuating the parking brake lever to its fully applied position one time after tightening the adjustment nut will yield (stretch) the bent nail portion of the equalizer approximately 1/4 inch. This process will correctly set the parking brake cable tension. 15. Adjust parking brake cable tension using the following steps: a. Place the parking brake lever in the fully released (down) position. b. Tighten the adjusting nut (3) on the parking brake lever output cable until 31 millimeters of thread is out past the end of the adjustment nut (1). c. Actuate the parking brake lever to its fully applied position one time, then reposition it to its fully released (down) position. 16. Raise the vehicle to a point where the rear wheels just clear the floor. 17. Check the rear wheels of the vehicle; they should rotate freely without dragging. 18. Apply the parking brake. Check the rear wheels of the vehicle. They should not rotate. 19. Return the parking brake lever to its fully released (down) position and check the rear wheels. They should rotate freely without dragging. 20. Apply the parking brake. 21. Lower the vehicle. 22. Install the center console. 23. Remove the blocks from the tires and wheel assemblies. 24. Connect the battery negative cable to its post on the battery. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Removal Parking Brake Lever: Service and Repair Removal REMOVAL NOTE: Refer to Warnings and Cautions. NOTE: The procedure below applies to either of the two rear parking brake cables. 1. Disconnect and isolate the battery negative cable from its post on the battery. 2. Block the tire and wheel assemblies so the vehicle does not move once the vehicle parking brake lever is released. 3. Remove the center console. 4. Release and lower the parking brake lever (5). 5. Loosen the adjusting nut on the lever's output cable taking tension off parking brake cables. Back the nut off until it is flush with the end of the output cable. 6. Remove the parking brake cables (3) from the parking brake cable equalizer (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Removal > Page 5282 7. Disconnect the wiring harness connector (2) from the parking brake switch (3). 8. Remove the nuts (1) attaching the parking brake lever (6) to the vehicle. 9. Remove the parking brake lever (6). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Removal > Page 5283 Parking Brake Lever: Service and Repair Installation INSTALLATION 1. Place the parking brake lever (6) on the mounting studs (5) affixed to the vehicle floor pan. Install and tighten the nuts to 28 Nm (250 in. lbs.). 2. Connect the wiring harness connector (2) to the parking brake switch (3). CAUTION: A NEW parking brake cable equalizer (2) must be installed when servicing the parking brake cables or lever. The equalizer has an integrated bent nail tensioner that needs to be stretched upon installation placing the correct tension on the cables. 3. Remove and install a NEW parking brake cable equalizer (2) on the parking brake lever output cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Removal > Page 5284 4. Install the rear parking brake cables (3) into the equalizer (2) on the parking brake lever output cable. 5. Ensure that the parking brake cables are correctly installed on the equalizer and aligned with the cable track on the parking brake lever. NOTE: Actuating the parking brake lever to its fully applied position one time after tightening the adjustment nut will yield (stretch) the bent nail portion of the equalizer approximately 6 mm (1/4 inch). This process will correctly set the parking brake cable tension. 6. Adjust parking brake cable tension using the following steps: a. Place the parking brake lever in the fully released (down) position. b. Tighten the adjusting nut (3) on the parking brake lever output cable until 31 millimeters (1.220 inches) of thread is out past the end of the adjustment nut (1). c. Actuate the parking brake lever to its fully applied position one time, then reposition it to its fully released (down) position. 7. Raise the vehicle to a point where the rear wheels just clear the floor. 8. Check the rear wheels of the vehicle; they should rotate freely without dragging. 9. Apply the parking brake. Check the rear wheels of the vehicle. They should not rotate. 10. Return the parking brake lever to its fully released (down) position and check the rear wheels. They should rotate freely without dragging. 11. Apply the parking brake. 12. Lower the vehicle. 13. Install the center console. 14. Remove the blocks from the tires and wheel assemblies. 15. Connect the battery negative cable to its post on the battery. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments Parking Brake Shoe: Adjustments PARKING BRAKE SHOE ADJUSTMENT NOTE: Refer to Warnings and Cautions. NOTE: The parking brake shoes used in the drum-in-hat park brake system do not automatically adjust to compensate for brake shoe lining wear. Therefore, it is necessary to manually adjust the parking brake shoes. 1. Verify the parking brake lever is in the released (down) position. 2. Raise and support the vehicle. 3. Remove the wheel mounting nuts (3), then the tire and wheel assembly. 4. Install a couple wheel mounting nuts to hold the brake rotor in place while adjustment of the brake shoes is made. NOTE: To find the adjuster wheel with the drum on position the hole (1) in the front of the rotor drum as follows: - Left side - 7 o'clock. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 5288 - Right side - 5 o'clock. NOTE: When adjusting the parking brake shoes with the drum-in hat rotor installed, rotating the adjuster wheel (2) upward will loosen the adjustment. Rotating the adjuster wheel (2) downward will tighten the adjustment. 5. Remove the rubber plug from the hole (1) in the front of the rotor. 6. Utilizing the hole (1) in the front of the rotor, make a fine adjustment of the shoes. 7. Reinstall the rubber plug. 8. Lower the vehicle far enough to access the interior of the vehicle. 9. Reach inside the vehicle and cycle (fully apply and release) the park brakes. 10. With the parking brake lever in the fully applied (up) position, attempt to hand rotate each rear brake rotor to ensure that the parking brake shoes are working properly. 11. With the parking brake lever in the released (down) position, hand rotate each rear brake rotor to ensure that the parking brake shoes are not dragging. 12. Raise and support the vehicle. 13. Remove the wheel mounting nuts and install the tire and wheel assembly (1). Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 14. Lower the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Removal Parking Brake Shoe: Service and Repair Removal REMOVAL NOTE: Refer to Warnings and Cautions. 1. Raise and support the vehicle. NOTE: If removing parking brake shoes on both sides of vehicle, perform remaining steps on each side of the vehicle. 2. Access and remove the rear brake rotor (3). 3. Turn the brake shoe adjuster wheel until the adjuster is at shortest length. 4. Remove the upper return spring (1) from the anchor pin (3) and the rear brake shoe. 5. Remove the upper return spring (2) from the anchor pin (3) and the front brake shoe. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Removal > Page 5291 6. Remove the brake shoe hold-down springs and pins (1, 2). Rotate the pins 90° to disengage. 7. Remove the parking brake cable from the lever on the rear parking brake shoe. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Removal > Page 5292 8. Remove the brake shoes (2, 6), adjuster (5) and lower return spring (3) as an assembly from the support plate. 9. If necessary, remove the strut (1). 10. Remove the lower return spring (3) and adjuster (5) from the shoes (2, 6). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Removal > Page 5293 Parking Brake Shoe: Service and Repair Installation INSTALLATION NOTE: If replacing parking brake shoes on both sides of vehicle, perform STEP 1 through STEP 15 on each side of the vehicle to complete shoe set installation, then proceed to STEP 16. NOTE: Left side shoes are shown in the figure. Right side shoes are a mirror image of the left except for the adjuster. The threaded portion of the adjuster should always be positioned to the left side in order to maintain consistent side-to-side rotational direction for adjustment purposes. 1. Install the lower return spring (3) and adjuster (5) between the parking brake shoes (2, 6). The rear shoe will have the lever mounted on the inside. Make sure the threaded portion of the adjuster is mounted to the left on both right and left side parking brake assemblies (see preceding note). 2. If necessary, place the strut (1) above the hub and bearing on the vehicle. Note the curved end of the strut (1) is positioned to the rear. 3. Install the assembled brake shoes (2, 6), adjuster (5) and lower return spring (3) over the hub and bearing and onto the support plate and anchor. Be sure to install the strut between the front shoe and the lever on the rear shoe. 4. Install the parking brake cable onto the lever on the parking brake shoe. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Removal > Page 5294 5. Install the brake shoe hold-down springs and pins (1, 2). Rotate the pins 90° to engage. 6. Install the front upper return spring (2) holding the front brake shoe and anchor pin (3). 7. Install the rear upper return spring (2) holding the rear brake shoe and anchor pin (3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Removal > Page 5295 8. Using Brake Shoe Gauge, Special Tool C-3919, or equivalent, measure the inside diameter of parking brake drum portion of rotor. Set the Gauge. 9. Place Gauge (2) over the parking brake shoes (1) at their widest point. 10. Using the adjuster wheel, adjust the parking brake shoes until the linings on both parking brake shoes just touch the jaws on the Gauge. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Removal > Page 5296 11. Install the rear brake rotor (3) and install a couple wheel mounting nuts to hold it in place while a final adjustment is made. NOTE: To find the adjuster wheel with the drum on position the hole (1) in the front of the rotor drum as follows: - Left side - 7 o'clock. - Right side - 5 o'clock. NOTE: When adjusting the parking brake shoes with the drum-in hat rotor installed, rotating the adjuster wheel (2) upward will loosen the adjustment. Rotating the adjuster wheel (2) downward will tighten the adjustment. 12. Remove the rubber plug from the hole (1) in the front of the rotor. 13. Utilizing the hole (1) in the front of the rotor, make a final adjustment of the shoes if necessary. 14. Reinstall the rubber plug. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Removal > Page 5297 15. Remove the wheel mounting nuts and finish installing the brake rotor (3) as well as all components removed to access it. 16. Lower the vehicle. 17. Cycle the parking brake lever once, verifying proper operation of the parking brake. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Component ID: 348 Component : SWITCH-PARKING BRAKE Connector: Name : SWITCH-PARKING BRAKE Color : NATURAL # of pins : 1 Pin Description Circuit 1 PARK BRAKE SWITCH SENSE B25 20DG/WT Component Location - 35 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 5301 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 5302 Parking Brake Warning Switch: Diagrams Component ID: 348 Component : SWITCH-PARKING BRAKE Connector: Name : SWITCH-PARKING BRAKE Color : NATURAL # of pins : 1 Pin Description Circuit 1 PARK BRAKE SWITCH SENSE B25 20DG/WT Component Location - 35 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 5303 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation Vacuum Brake Booster: Description and Operation DESCRIPTION The power brake booster (3) is mounted to the engine side of the dash panel. The master cylinder is bolted to the front of the booster. A vacuum check valve is also mounted on the front of the booster. A vacuum line connects the check valve to engine source vacuum. The booster input rod extends through the dash panel and connects to the brake pedal. This vehicle uses a 254 mm single diaphragm power brake booster. Power brake boosters are internally tuned differently depending on whether the vehicle is equipped with ABS or without ABS. If the power brake booster requires replacement, be sure it is replaced with the correct part. The power brake booster can be identified by the tag attached to the body of the booster. This tag contains the following information: - The production part number - The date it was built, and - The booster manufacturer. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > Page 5308 Vacuum Brake Booster: Testing and Inspection POWER BRAKE BOOSTER BASIC TEST 1. With engine off, depress and release the brake pedal several times to purge all vacuum from the power brake booster. 2. Depress and hold the pedal with light effort (15 to 25 lbs. (6.8 to 11.3 kg) pressure), then start the engine. The pedal should fall slightly, then hold. Less effort should be needed to apply the pedal at this time. If the pedal fell as indicated, perform the VACUUM LEAK TEST listed after the BASIC TEST. If the pedal did not fall, continue on with this BASIC TEST. 3. Disconnect the vacuum hose at the vacuum check and tee-in a vacuum gauge. 4. Start the engine. 5. When the engine is at warm operating temperature, allow it to idle and check the vacuum at the gauge. If the vacuum supply is 12 inches Hg (40.5 kPa) or more, the power brake booster is defective and must be replaced. If the vacuum supply is below 12 inches Hg, continue on with this BASIC TEST. 6. Shut off the engine. 7. Connect the vacuum gauge to the vacuum reference port on the engine intake manifold. 8. Start the engine and observe the vacuum gauge. If the vacuum is still low, check the engine tune and repair as necessary. If the vacuum is above 12 inches, the hose or check to the booster has a restriction or leak. Once an adequate vacuum supply is obtained, repeat the BASIC TEST. VACUUM LEAK TEST 1. Disconnect the vacuum hose at the vacuum check and tee-in a vacuum gauge. 2. Start the engine. 3. Allow the engine to warm up to normal operating temperature and engine idle. 4. Using vacuum line pliers, close off the vacuum supply hose near the booster and observe the vacuum gauge. If the vacuum drop exceeds 1.0 inch Hg (3.3 kPa) in one minute, repeat the above steps to confirm the reading. The vacuum loss should be less than 1.0 inch Hg in one minute time span. If the loss is more than 1.0 inch Hg, replace the power brake booster. If it is not, continue on with this test. 5. Remove the pliers from the hose temporarily. 6. Apply light effort (approximately 15 lbs. (6.8 kg) of force) to the brake pedal and hold the pedal steady. Do not move the pedal once the pressure is applied or the test results may vary. 7. Have an assistant reattach the pliers to the vacuum supply hose. 8. Allow 5 seconds for stabilization, then observe the vacuum gauge. If the vacuum drop exceeds 3.0 inches Hg (10 kPa) in 15 seconds, repeat the above steps to confirm the reading. The vacuum loss should be less than 3.0 inches Hg in 15 seconds time span. If the loss is more than 3.0 inches Hg, replace the power brake booster. If it is not, the booster is not defective. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Removal Vacuum Brake Booster: Service and Repair Removal POWER BRAKE BOOSTER NOTE: Refer to Warnings and Cautions. 1. Disconnect and isolate the battery negative cable from its post on the battery. 2. Remove the master cylinder. 3. Disconnect the vacuum hose (2) from the check valve (1) on the power brake booster. Do not remove the check valve from power brake booster. 4. Remove the steering column opening cover (and airbag if equipped) on the instrument panel. 5. Remove the mounting screws (2) and reinforcement (1) behind the steering column opening cover. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Removal > Page 5311 6. Remove the stop lamp switch (2) and discard it. Do not reuse the stop lamp switch. 7. Remove the retaining clip (2) securing the power brake booster push rod (1) to the brake pedal. To do so, position a small screwdriver under the center tang of the retaining clip, then rotate the screwdriver enough to allow the retaining clip tang to pass over the end of the brake pedal pin (3). Remove and discard the clip. Do not reuse the clip. 8. Slide the booster push rod (1) off the brake pedal pin (3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Removal > Page 5312 9. Remove the four nuts (4) attaching the power brake booster (3) to the dash panel. 10. Slide the power brake booster (3) forward until its mounting studs clear the dash panel, then remove it through the engine compartment. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Removal > Page 5313 Vacuum Brake Booster: Service and Repair Installation POWER BRAKE BOOSTER NOTE: Before power brake booster (1) installation, be certain a NEW dash seal (2) is installed on the booster mounting studs. 1. Install the power brake booster (3) by sliding the push rod and studs through the dash panel and into mounting position. 2. Under the instrument panel, install the four power brake booster mounting nuts (4). To tighten the nuts, refer to the following step. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Removal > Page 5314 CAUTION: Because of power brake booster design, it is very important to tighten the mounting nuts in the proper sequence. 3. Tighten the brake pedal/booster mounting nuts in the proper sequence to 23 Nm (17 ft. lbs.). 4. Using Mopar(R) Lubriplate, or an equivalent, coat the surface of the brake pedal pin (3) where it contacts the brake booster input rod (1). 5. Install the power brake booster push rod (1) on the pin (3) mounted on the side of the brake pedal. Install a NEW retaining clip (2) on the end of the pin. Do not reuse the old clip. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Removal > Page 5315 CAUTION: Do not reuse the original stop lamp switch. The switch can only be adjusted once. That is during initial installation of the switch. If the switch is not adjusted properly or has been removed for some service, a new switch must be installed and adjusted. 6. Install and adjust a NEW stop lamp switch (2) in the brake pedal bracket (1). 7. Install the steering column opening cover reinforcement (1) in the steering column opening. Install the mounting screws (2). 8. Install the steering column opening cover (and airbag if equipped) on the instrument panel. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Removal > Page 5316 CAUTION: When installing the vacuum hose on the check valve (1), make sure the hose is routed properly to avoid possible contact with unfriendly surfaces. 9. Connect the vacuum hose (2) to the vacuum check valve (1). 10. Install the master cylinder. 11. Connect the battery negative cable to its post on the battery. 12. Bleed the base brake system if necessary. WARNING: Be certain a firm brake pedal is achieved prior to attempting to operate the vehicle. 13. Road test the vehicle to ensure proper operation of the brakes. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > F50 > Feb > 07 > Recall - ABS Module Reprogramming Technical Service Bulletin # F50 Date: 070212 Recall - ABS Module Reprogramming February 2007 Dealer Service Instructions for: Safety Recall F50 Reprogram ABS Control Module Models 2007 (LX) Chrysler 300, Dodge Charger and Magnum - built from September 7, 2006 through November 18, 2006 (MDH 090701 - 111801). 2007 (JS) Chrysler Sebring - built from October 10, 2006 through November 15, 2006 (MDH 101019 - 111509). 2007 (PM) Dodge Caliber - built from September 7, 2006 through November 18, 2006 (MDH 090707 - 111801). 2007 (MK49) Jeep(R) Compass - built from September 7, 2006 through November 18, 2006 (MDH 090707 - 111801). 2007 (MK74) Jeep Patriot - built from September 7, 2006 through November 18, 2006 (MDH 090707 - 111801). 2007 (WK) Jeep Grand Cherokee - built from October 18, 2006 through December 6, 2006 (MDH 101813 - 120606). 2007 (XK) Jeep Commander - built from October 18, 2006 through December 6, 2006 (MDH 101813 - 120606). 2007 (KJ) Jeep Liberty - built from September 18, 2006 through November 30, 2006 (MDH 091807 - 113018). 2007 (KA) Dodge Nitro - built from September 18, 2006 through November 30, 2006 (MDH 091807 - 113018). 2007 (JK) Jeep Wrangler - built from November 9, 2006 through December 8, 2006 (MDH 110914 120811). NOTE: This recall applies only to the above vehicles equipped with an ESP/ABS system (sales code BNB, BRF, BRY, BR1 or BR3). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The software programmed into the Anti-Lock Brake System (ABS) control module on about 50,600 of the above vehicles may cause the rear brakes to lock up during certain braking conditions. This could result in a loss of vehicle control and cause a crash without warning. Repair The ABS control module must be reprogrammed (flashed). Parts Information No parts are required to perform this service procedure. Special Tools Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > F50 > Feb > 07 > Recall - ABS Module Reprogramming > Page 5326 The existing special tools may be required to perform this repair. NOTE: The StarSCAN and the Star Mobile scan tools must be at version 7.03 or higher before this procedure can be performed. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is shown. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > F50 > Feb > 07 > Recall - ABS Module Reprogramming > Page 5327 The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure NOTE: Reprogramming of the ABS Control Module can be performed using the StarSCAN scan tool or the StarMOBILE scan tool. A. Reprogram the ABS Control Module Using StarSCAN NOTE: The StarSCAN tool must be at version 7.03 or higher before this procedure can be performed. The software release level is visible in the blue header at the top of the StarSCAN screen. 1. Open the hood and install a battery charger. Verify that the charging rate provides approximately 13.5 volts. 2. Use the following procedure to determine the ABS Control Module software part number: a. Connect the StarSCAN to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. b. Power ON the StarSCAN. c. From the StarSCAN Home Screen, select "ECU View". d. From the StarSCAN ECU View Screen, select "ABS" from the list of modules. e. Select "More Options" and then select "ECU Flash". f. Record the part number displayed at the top of the "Flash ABS" screen for later reference. 3. Connect the CH9410 ethernet cable to the StarSCAN and the dealer's network drop. 4. Select "Browse for New File" and follow the on screen instructions. 5. Highlight the calibration and then select "Download to Scantool". 6. Select "Close" after the download is complete, disconnect the ethernet cable from the scan tool and then select "Back". 7. Highlight the listed calibration. 8. Select "Update Controller" and follow the screen instructions. 9. When the ABS control module update is complete, select "OK". 10. Verify the part number (resident flash file) at the top of the screen has updated to the new part number. 11. After completing the ABS control module reprogramming, clear all Diagnostic Trouble Codes (DTC's) using the following procedure: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > F50 > Feb > 07 > Recall - ABS Module Reprogramming > Page 5328 a. Return to the "Main Menu" (Home Page). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's" and follow the screen prompts. 12. Disconnect and remove the StarSCAN and battery charger from the vehicle. B. Reprogram the ABS Control Module Using StarMOBILE NOTE: The StarMOBILE scan tool must be at version 7.03 or higher before this procedure can be performed. 1. Open the hood and install a battery charger. Verify that the charging rate provides approximately 13.5 volts. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. Connect the CH9410 ethernet cable to the StarMOBILE and the dealer's network drop. 5. From the desktop, launch the "StarMOBILE Desktop Client" software. 6. From the main menu on the StarMOBILE, select "System Status". 7. Establish a connection with the StarMOBILE scan tool. 8. Select "Flash Download". 9. Select "Next" and then enter your ID and password. 10. Enter the vehicle information (manually or use the automatic function). 11. Highlight the required flash file and select "Download to Client". 12. Select "BACK" then select "ECU View". 13. Select "ABS Antilock Brakes". 14. Select "More Options". 15. Select "ECU Flash". 16. Select "Manage Files". 17. Highlight downloaded flash file. 18. Select "Copy to SM Devise" and then follow the screen prompts. 19. Disconnect the ethernet cable from the StarMOBILE scan tool. 20. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 21. From the "System Status" screen press the "Exit" button. 22. From the "Main Menu" select "Enter Standalone Diagnostic Mode". 23. Select "ECU View" and press the select button. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > F50 > Feb > 07 > Recall - ABS Module Reprogramming > Page 5329 24. Highlight "ABS" and press the select button. 25. Select "Flash ECU" and press the select button. 26. Verify the file number on the screen. If correct, press the select button and follow the screen prompts. 27. When the flash is complete, press the "OK" button. 28. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Return to the "Main Menu" (Home Page). b. From the "Home" screen, select "System View" and then select "All DTC's". c. Select the "Clear All Stored DTC's" and follow screen prompts. 29. Disconnect the StarMOBILE scan tool and battery charger from the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > F50 > Feb > 07 > Recall - ABS Module Reprogramming > Page 5330 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > NHTSA06V493000 > Dec > 06 > Recall 06V493000: ABS Control Module Software Update Electronic Brake Control Module: Recalls Recall 06V493000: ABS Control Module Software Update MAKE/MODELS: MODEL/BUILD YEARS: Chrysler/300 2007 Chrysler/Sebring 2007 Dodge/Caliber 2007 Dodge/Charger 2007 Dodge/Magnum 2007 Dodge/Nitro 2007 Jeep/Commander 2007 Jeep/Compass 2007 Jeep/Grand Cherokee 2007 Jeep/Liberty 2007 Jeep/Wrangler 2007 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 06V493000 MFG'S REPORT DATE: December 22, 2006 COMPONENT: Service Brakes, Hydraulic: Antilock: Control Unit/Module POTENTIAL NUMBER OF UNITS AFFECTED: 62369 SUMMARY: On certain vehicles, the Antilock Brake System (ABS) control module software may cause the rear brakes to lock up during certain braking conditions. CONSEQUENCE: This could result in a loss of vehicle control and cause a crash without warning. REMEDY: Dealers will reprogram the ABS electronic control unit. The recall is expected to begin during February 2007. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. F50. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > F50 > Feb > 07 > Recall - ABS Module Reprogramming Technical Service Bulletin # F50 Date: 070212 Recall - ABS Module Reprogramming February 2007 Dealer Service Instructions for: Safety Recall F50 Reprogram ABS Control Module Models 2007 (LX) Chrysler 300, Dodge Charger and Magnum - built from September 7, 2006 through November 18, 2006 (MDH 090701 - 111801). 2007 (JS) Chrysler Sebring - built from October 10, 2006 through November 15, 2006 (MDH 101019 - 111509). 2007 (PM) Dodge Caliber - built from September 7, 2006 through November 18, 2006 (MDH 090707 - 111801). 2007 (MK49) Jeep(R) Compass - built from September 7, 2006 through November 18, 2006 (MDH 090707 - 111801). 2007 (MK74) Jeep Patriot - built from September 7, 2006 through November 18, 2006 (MDH 090707 - 111801). 2007 (WK) Jeep Grand Cherokee - built from October 18, 2006 through December 6, 2006 (MDH 101813 - 120606). 2007 (XK) Jeep Commander - built from October 18, 2006 through December 6, 2006 (MDH 101813 - 120606). 2007 (KJ) Jeep Liberty - built from September 18, 2006 through November 30, 2006 (MDH 091807 - 113018). 2007 (KA) Dodge Nitro - built from September 18, 2006 through November 30, 2006 (MDH 091807 - 113018). 2007 (JK) Jeep Wrangler - built from November 9, 2006 through December 8, 2006 (MDH 110914 120811). NOTE: This recall applies only to the above vehicles equipped with an ESP/ABS system (sales code BNB, BRF, BRY, BR1 or BR3). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The software programmed into the Anti-Lock Brake System (ABS) control module on about 50,600 of the above vehicles may cause the rear brakes to lock up during certain braking conditions. This could result in a loss of vehicle control and cause a crash without warning. Repair The ABS control module must be reprogrammed (flashed). Parts Information No parts are required to perform this service procedure. Special Tools Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > F50 > Feb > 07 > Recall - ABS Module Reprogramming > Page 5340 The existing special tools may be required to perform this repair. NOTE: The StarSCAN and the Star Mobile scan tools must be at version 7.03 or higher before this procedure can be performed. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is shown. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > F50 > Feb > 07 > Recall - ABS Module Reprogramming > Page 5341 The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure NOTE: Reprogramming of the ABS Control Module can be performed using the StarSCAN scan tool or the StarMOBILE scan tool. A. Reprogram the ABS Control Module Using StarSCAN NOTE: The StarSCAN tool must be at version 7.03 or higher before this procedure can be performed. The software release level is visible in the blue header at the top of the StarSCAN screen. 1. Open the hood and install a battery charger. Verify that the charging rate provides approximately 13.5 volts. 2. Use the following procedure to determine the ABS Control Module software part number: a. Connect the StarSCAN to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. b. Power ON the StarSCAN. c. From the StarSCAN Home Screen, select "ECU View". d. From the StarSCAN ECU View Screen, select "ABS" from the list of modules. e. Select "More Options" and then select "ECU Flash". f. Record the part number displayed at the top of the "Flash ABS" screen for later reference. 3. Connect the CH9410 ethernet cable to the StarSCAN and the dealer's network drop. 4. Select "Browse for New File" and follow the on screen instructions. 5. Highlight the calibration and then select "Download to Scantool". 6. Select "Close" after the download is complete, disconnect the ethernet cable from the scan tool and then select "Back". 7. Highlight the listed calibration. 8. Select "Update Controller" and follow the screen instructions. 9. When the ABS control module update is complete, select "OK". 10. Verify the part number (resident flash file) at the top of the screen has updated to the new part number. 11. After completing the ABS control module reprogramming, clear all Diagnostic Trouble Codes (DTC's) using the following procedure: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > F50 > Feb > 07 > Recall - ABS Module Reprogramming > Page 5342 a. Return to the "Main Menu" (Home Page). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's" and follow the screen prompts. 12. Disconnect and remove the StarSCAN and battery charger from the vehicle. B. Reprogram the ABS Control Module Using StarMOBILE NOTE: The StarMOBILE scan tool must be at version 7.03 or higher before this procedure can be performed. 1. Open the hood and install a battery charger. Verify that the charging rate provides approximately 13.5 volts. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. Connect the CH9410 ethernet cable to the StarMOBILE and the dealer's network drop. 5. From the desktop, launch the "StarMOBILE Desktop Client" software. 6. From the main menu on the StarMOBILE, select "System Status". 7. Establish a connection with the StarMOBILE scan tool. 8. Select "Flash Download". 9. Select "Next" and then enter your ID and password. 10. Enter the vehicle information (manually or use the automatic function). 11. Highlight the required flash file and select "Download to Client". 12. Select "BACK" then select "ECU View". 13. Select "ABS Antilock Brakes". 14. Select "More Options". 15. Select "ECU Flash". 16. Select "Manage Files". 17. Highlight downloaded flash file. 18. Select "Copy to SM Devise" and then follow the screen prompts. 19. Disconnect the ethernet cable from the StarMOBILE scan tool. 20. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 21. From the "System Status" screen press the "Exit" button. 22. From the "Main Menu" select "Enter Standalone Diagnostic Mode". 23. Select "ECU View" and press the select button. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > F50 > Feb > 07 > Recall - ABS Module Reprogramming > Page 5343 24. Highlight "ABS" and press the select button. 25. Select "Flash ECU" and press the select button. 26. Verify the file number on the screen. If correct, press the select button and follow the screen prompts. 27. When the flash is complete, press the "OK" button. 28. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Return to the "Main Menu" (Home Page). b. From the "Home" screen, select "System View" and then select "All DTC's". c. Select the "Clear All Stored DTC's" and follow screen prompts. 29. Disconnect the StarMOBILE scan tool and battery charger from the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > F50 > Feb > 07 > Recall - ABS Module Reprogramming > Page 5344 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > NHTSA06V493000 > Dec > 06 > Recall 06V493000: ABS Control Module Software Update Electronic Brake Control Module: All Technical Service Bulletins Recall 06V493000: ABS Control Module Software Update MAKE/MODELS: MODEL/BUILD YEARS: Chrysler/300 2007 Chrysler/Sebring 2007 Dodge/Caliber 2007 Dodge/Charger 2007 Dodge/Magnum 2007 Dodge/Nitro 2007 Jeep/Commander 2007 Jeep/Compass 2007 Jeep/Grand Cherokee 2007 Jeep/Liberty 2007 Jeep/Wrangler 2007 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 06V493000 MFG'S REPORT DATE: December 22, 2006 COMPONENT: Service Brakes, Hydraulic: Antilock: Control Unit/Module POTENTIAL NUMBER OF UNITS AFFECTED: 62369 SUMMARY: On certain vehicles, the Antilock Brake System (ABS) control module software may cause the rear brakes to lock up during certain braking conditions. CONSEQUENCE: This could result in a loss of vehicle control and cause a crash without warning. REMEDY: Dealers will reprogram the ABS electronic control unit. The recall is expected to begin during February 2007. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. F50. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 5349 Electronic Brake Control Module: Locations Component ID: 146 Component : MODULE-ANTI-LOCK BRAKES Connector: Name : MODULE-ANTI-LOCK BRAKES Color : BLACK # of pins : 47 Gender : FEMALE Pin Description Circuit 1 FUSED B(+) (PUMP) A921 12RD/DB 2-3-4-5-6-- 7-8 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 9-10 - 11 - 12 CAN C BUS (+) D65 20WT/BK 13 CAN C BUS (-) D64 20WT/LB 14 - 15 - 16 GROUND Z909 12BK/WT 17 - 18 DYNAMICS SENSOR HIGH DATA LINK D465 20WT/DB 19 DYNAMICS SENSOR LOW DATA LINK D464 20WT/YL 20 - 21 - 22 DYNAMICS SENSOR SUPPLY G4 18VT/LB 23 - 24 - 25 - 26 - 27 - 28 - 29 DYNAMICS SENSOR GROUND G94 18VT/DB 30 - 31 - 32 FUSED B(+) (VALVE) A922 14RD/BK 33 RIGHT FRONT WHEEL SPEED SENSOR SIGNAL B6 20WT/DB 34 RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY B7 20WT Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 5350 35 - 36 LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY B4 20LG 37 LEFT REAR WHEEL SPEED SENSOR SIGNAL B3 20LG/DB 38 - 39 - 40 - 41 - 42 RIGHT REAR WHEEL SPEED SENSOR SIGNAL B1 20YL/DB 43 RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY B2 20YL 44 - 45 LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY B9 20DG/LG 46 LEFT FRONT WHEEL SPEED SENSOR SIGNAL B8 20DG/TN 47 GROUND Z909 12BK/WT Component Location - 5 Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 5351 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 5352 Electronic Brake Control Module: Diagrams Component ID: 146 Component : MODULE-ANTI-LOCK BRAKES Connector: Name : MODULE-ANTI-LOCK BRAKES Color : BLACK # of pins : 47 Gender : FEMALE Pin Description Circuit 1 FUSED B(+) (PUMP) A921 12RD/DB 2-3-4-5-6-- 7-8 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 9-10 - 11 - 12 CAN C BUS (+) D65 20WT/BK 13 CAN C BUS (-) D64 20WT/LB 14 - 15 - 16 GROUND Z909 12BK/WT 17 - 18 DYNAMICS SENSOR HIGH DATA LINK D465 20WT/DB 19 DYNAMICS SENSOR LOW DATA LINK D464 20WT/YL 20 - 21 - 22 DYNAMICS SENSOR SUPPLY G4 18VT/LB 23 - 24 - 25 - 26 - 27 - 28 - 29 DYNAMICS SENSOR GROUND G94 18VT/DB 30 - 31 - 32 FUSED B(+) (VALVE) A922 14RD/BK 33 RIGHT FRONT WHEEL SPEED SENSOR SIGNAL B6 20WT/DB 34 RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY B7 20WT Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 5353 35 - 36 LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY B4 20LG 37 LEFT REAR WHEEL SPEED SENSOR SIGNAL B3 20LG/DB 38 - 39 - 40 - 41 - 42 RIGHT REAR WHEEL SPEED SENSOR SIGNAL B1 20YL/DB 43 RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY B2 20YL 44 - 45 LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY B9 20DG/LG 46 LEFT FRONT WHEEL SPEED SENSOR SIGNAL B8 20DG/TN 47 GROUND Z909 12BK/WT Component Location - 5 Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 5354 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Description Electronic Brake Control Module: Description and Operation Description DESCRIPTION The Antilock Brake Module (ABM) is a microprocessor-based device which monitors the antilock brake system (ABS) during normal braking and controls it when the vehicle is in an ABS stop or when in a traction control or Electronic Stability Program (ESP) situation. The ABM utilizes a 47-way electrical connector on the vehicle wiring harness. The power source for the ABM is through the ignition switch in the RUN or ON position. The ABM (1) is mounted to the HCU (2) as part of the Integrated Control Unit (ICU). The ICU is located in the engine compartment on the inboard side of the right body frame rail behind the strut tower. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Description > Page 5357 Electronic Brake Control Module: Description and Operation Operation OPERATION The primary functions of the Antilock Brake Module (ABM) are to: - Monitor the Antilock Brake System (ABS) and Electronic Stability Program (ESP) for proper operation. - Detect wheel locking or wheel slipping tendencies by monitoring the speed of all four wheels of the vehicle. - Control fluid modulation to the wheel brakes while the system is in ABS or traction control mode. - Modulates fluid pressure to the wheel brakes to control vehicle yaw rate in ESP mode. - Store diagnostic information. - Provide communication to the scan tool while in diagnostic mode. - Illuminate the amber ABS indicator in the instrument cluster. - Illuminate the yellow ESP/BAS indicator in the instrument cluster (if equipped). The ABM constantly monitors the ABS and ESP (if equipped) for proper operation. If the ABM detects a fault, it will turn on the amber ABS and yellow ESP/BAS indicators and disable the ABS or ESP if so equipped. The normal base braking system will remain operational at that time. The ABM continuously monitors the speed of each wheel through the signals generated by the wheel speed sensors to determine if any wheel is beginning to lock. When a wheel locking tendency is detected, the ABM commands the ABM solenoid coils to actuate. The coils then open and close the valves in the HCU that modulate brake fluid pressure in some or all of the hydraulic circuits. The ABM continues to control pressure in individual hydraulic circuits until a locking tendency is no longer present. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Removal Electronic Brake Control Module: Service and Repair Removal REMOVAL Due to packaging and limited space it is necessary to remove and disassemble the Integrated Control Unit (ICU) to service the Antilock Brake Module (ABM) on this vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Removal > Page 5360 Electronic Brake Control Module: Service and Repair Installation INSTALLATION Due to packaging and limited space it is necessary to install the Antilock Brake Module (ABM) on the Hydraulic Control Unit (HCU), then install the Integrated Control Unit (ICU) on the vehicle as an assembly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Brake Fluid Level Sensor/Switch: Locations Component ID: 283 Component : SENSOR-BRAKE FLUID LEVEL Connector: Name : SENSOR-BRAKE FLUID LEVEL Color : BLACK # of pins : 2 Pin Description Circuit 1 BRAKE FLUID LEVEL SWITCH SENSE B20 20DG/RD 2 GROUND Z925 20BK/YL Component Location - 6 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 5365 Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 5366 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 5367 Brake Fluid Level Sensor/Switch: Diagrams Component ID: 283 Component : SENSOR-BRAKE FLUID LEVEL Connector: Name : SENSOR-BRAKE FLUID LEVEL Color : BLACK # of pins : 2 Pin Description Circuit 1 BRAKE FLUID LEVEL SWITCH SENSE B20 20DG/RD 2 GROUND Z925 20BK/YL Component Location - 6 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 5368 Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 5369 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 5370 Brake Fluid Level Sensor/Switch: Description and Operation DESCRIPTION The brake fluid level switch (2) is mounted through the center of the fluid reservoir (1). The switch can be serviced separately from the master cylinder fluid reservoir. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Service and Repair > Removal Brake Fluid Level Sensor/Switch: Service and Repair Removal REMOVAL NOTE: Refer to Warnings and Cautions. 1. Remove the wiring harness connector (1) from the brake fluid level switch (2) in the master cylinder brake fluid reservoir. 2. Push together the retaining tabs (1) holding the brake fluid level switch in place in the brake fluid reservoir (2). 3. Pull the brake fluid level switch out the right side of the reservoir. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Service and Repair > Removal > Page 5373 Brake Fluid Level Sensor/Switch: Service and Repair Installation INSTALLATION 1. Align the brake fluid level switch with its mounting hole on the right side of the master cylinder brake fluid reservoir. Push the switch into the fluid reservoir until the switch retaining tabs (1) are expanded on the opposite side of the reservoir (2), locking it in place. 2. Connect the wiring harness connector (1) to the switch (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations Lateral Accelerometer: Locations Component ID: 288 Component : SENSOR-DYNAMICS Connector: Name : SENSOR-DYNAMICS Color : BLACK # of pins : 6 Qualifier : (ESP) Pin Description Circuit 1 DYNAMICS SENSOR LOW DATA LINK D464 20WT/YL 2 DYNAMICS SENSOR HIGH DATA LINK D465 20WT/DB 3 DYNAMICS SENSOR SUPPLY G4 18VT/LB 4-5 DYNAMICS SENSOR GROUND G94 18VT/DB 6-- Component Location - 45 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations > Page 5377 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations > Page 5378 Lateral Accelerometer: Diagrams Component ID: 288 Component : SENSOR-DYNAMICS Connector: Name : SENSOR-DYNAMICS Color : BLACK # of pins : 6 Qualifier : (ESP) Pin Description Circuit 1 DYNAMICS SENSOR LOW DATA LINK D464 20WT/YL 2 DYNAMICS SENSOR HIGH DATA LINK D465 20WT/DB 3 DYNAMICS SENSOR SUPPLY G4 18VT/LB 4-5 DYNAMICS SENSOR GROUND G94 18VT/DB 6-- Component Location - 45 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations > Page 5379 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations > Page 5380 Lateral Accelerometer: Description and Operation DESCRIPTION The Yaw Rate and Lateral Acceleration Sensors are housed into one unit known as the Dynamics Sensor (1). The sensor is used to measure side-to-side (Lateral) motion and vehicle rotational sensing (how fast the vehicle is turning - Yaw). Yaw and Lateral Acceleration Sensors cannot be serviced separately. The entire Dynamics Sensor must be replaced when necessary. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Service and Repair > Removal Lateral Accelerometer: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable from the battery post. 2. Remove the shifter housing center console. 3. Disconnect the wiring harness connector (3) at the dynamics sensor (1). 4. Remove the nuts (2) mounting the dynamics sensor to the floor pan tunnel (4). 5. Remove the dynamics sensor (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Service and Repair > Removal > Page 5383 Lateral Accelerometer: Service and Repair Installation INSTALLATION 1. Install the dynamics sensor (1) over the studs mounted to the floor pan tunnel (4). 2. Install the two mounting nuts (2). Tighten the nuts to 9 Nm (80 in. lbs.). 3. Connect the wiring harness connector (3) to the dynamics sensor (1). 4. Install the shifter housing center console. 5. Connect the battery negative cable to the battery post. It is important that this be performed properly. 6. Perform the Verification Test and clear any faults. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Component ID: 348 Component : SWITCH-PARKING BRAKE Connector: Name : SWITCH-PARKING BRAKE Color : NATURAL # of pins : 1 Pin Description Circuit 1 PARK BRAKE SWITCH SENSE B25 20DG/WT Component Location - 35 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 5387 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 5388 Parking Brake Warning Switch: Diagrams Component ID: 348 Component : SWITCH-PARKING BRAKE Connector: Name : SWITCH-PARKING BRAKE Color : NATURAL # of pins : 1 Pin Description Circuit 1 PARK BRAKE SWITCH SENSE B25 20DG/WT Component Location - 35 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 5389 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Locations Steering Angle Sensor: Locations Component ID: 316 Component : SENSOR-STEERING ANGLE Connector: Name : SENSOR-STEERING ANGLE Color : WHITE # of pins : 4 Pin Description Circuit 1 CAN C BUS (+) D265 20DB/LB 2 CAN C BUS (-) D264 20DB/WT 3 GROUND Z937 20BK/YL 4 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY Component Location - 28 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Locations > Page 5393 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Locations > Page 5394 Steering Angle Sensor: Diagrams Component ID: 316 Component : SENSOR-STEERING ANGLE Connector: Name : SENSOR-STEERING ANGLE Color : WHITE # of pins : 4 Pin Description Circuit 1 CAN C BUS (+) D265 20DB/LB 2 CAN C BUS (-) D264 20DB/WT 3 GROUND Z937 20BK/YL 4 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY Component Location - 28 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Locations > Page 5395 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Locations > Page 5396 Steering Angle Sensor: Description and Operation DESCRIPTION The steering angle sensor is an integral part of the clockspring (3) mounted on the steering column. Refer to CLOCKSPRING - DESCRIPTION) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Description and Operation Traction Control Switch: Description and Operation DESCRIPTION The ESP Off Switch is part of the accessory switch bank module located in the center bezel on the instrument panel above the transmission gear shifter. The ESP Off switch turns the Electronic Stability Program off whenever the switch is depressed. Depressing the switch a second time turns the ESP(R) back on. The switch resets itself each time the ignition is cycled. When the ESP Off switch is depressed and released, turning ESP(R) off, it does not completely turn the system off. The ESP(R) system reduces torque management to a lesser amount, but ESP(R) function can still occur if the system perceives the need. The ESP Off switch is serviced as part of the accessory switch bank. There are different accessory switch banks available based on the option content of the vehicle. Ensure the accessory switch bank being installed matches the vehicle options. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Service and Repair > Removal Traction Control Switch: Service and Repair Removal REMOVAL NOTE: The ESP Off switch is integral to the accessory switch bank and cannot be serviced separately. 1. Disconnect and isolate the negative battery cable. 2. Remove the center bezel from the instrument panel and place it on a work bench. 3. Remove the screws that secure the accessory switch bank to the back of the center bezel and remove the accessory switch bank. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Service and Repair > Removal > Page 5402 Traction Control Switch: Service and Repair Installation INSTALLATION NOTE: The ESP Off switch is serviced as part of the accessory switch bank. NOTE: There are different instrument panel accessory switch banks available based on the option content of the vehicle. Ensure the accessory switch bank being installed matches the vehicle options. 1. Position the accessory switch bank onto the back of the instrument panel center bezel. 2. Install the screws that secure the accessory switch bank to the center bezel. Tighten the screws to 2 Nm (17 in. lbs.). 3. Install the center bezel onto the instrument panel. 4. Reconnect the negative battery cable. 5. Perform the ABS Verification Test and make sure the ESP Off switch operates properly. 6. Verify proper operation of all components controlled by the switch bank. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front Wheel Speed Sensor: Locations Sensor-Wheel Speed-ABS-Left Front Component ID: 319 Component : SENSOR-WHEEL SPEED-ABS-LEFT FRONT Connector: Name : SENSOR-WHEEL SPEED-ABS-LEFT FRONT Color : BLACK # of pins : 2 Pin Description Circuit 1 LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY B9 20DG/LG 2 LEFT FRONT WHEEL SPEED SENSOR SIGNAL B8 20DG/TN Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 5407 Connector: Name : SENSOR-WHEEL SPEED-ABS-LEFT FRONT Color : # of pins : 2 Qualifier : (SENSOR SIDE) Pin Description Circuit 1 LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY DG/LG 2 LEFT FRONT WHEEL SPEED SENSOR SIGNAL DG/TN Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 5408 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 5409 Wheel Speed Sensor: Locations Sensor-Wheel Speed-ABS-Left Rear Component ID: 320 Component : SENSOR-WHEEL SPEED-ABS-LEFT REAR Connector: Name : SENSOR-WHEEL SPEED-ABS-LEFT REAR Color : BLACK # of pins : 2 Pin Description Circuit 1 LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY B4 20LG/BK 2 LEFT REAR WHEEL SPEED SENSOR SIGNAL B3 20LG/DB Component Location - 60 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 5410 Connector: Name : SENSOR-WHEEL SPEED-ABS-LEFT REAR Color : # of pins : 2 Qualifier : (SENSOR SIDE) Pin Description Circuit 1 LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY LG 2 LEFT REAR WHEEL SPEED SENSOR SIGNAL LG/DB Component Location - 60 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 5411 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 5412 Wheel Speed Sensor: Locations Sensor-Wheel Speed-ABS-Right Front Component ID: 321 Component : SENSOR-WHEEL SPEED-ABS-RIGHT FRONT Connector: Name : SENSOR-WHEEL SPEED-ABS-RIGHT FRONT Color : BLACK # of pins : 2 Pin Description Circuit 1 RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY B7 20WT 2 RIGHT FRONT WHEEL SPEED SENSOR SIGNAL B6 20WT/DB Component Location - 5 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 5413 Component Location - 6 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 5414 Connector: Name : SENSOR-WHEEL SPEED-ABS-RIGHT FRONT Color : # of pins : 2 Qualifier : (SENSOR SIDE) Pin Description Circuit 1 RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY WT 2 RIGHT FRONT WHEEL SPEED SENSOR SIGNAL WT/DB Component Location - 5 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 5415 Component Location - 6 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 5416 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 5417 Wheel Speed Sensor: Locations Sensor-Wheel Speed-ABS-Right Rear Component ID: 322 Component : SENSOR-WHEEL SPEED-ABS-RIGHT REAR Connector: Name : SENSOR-WHEEL SPEED-ABS-RIGHT REAR Color : BLACK # of pins : 2 Pin Description Circuit 1 RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY B2 20DG/LB 2 RIGHT REAR WHEEL SPEED SENSOR SIGNAL B1 20DG/OR 2 RIGHT REAR WHEEL SPEED SENSOR SIGNAL B1 20YL/DB Component Location - 63 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 5418 Connector: Name : SENSOR-WHEEL SPEED-ABS-RIGHT REAR Color : # of pins : 2 Qualifier : (SENSOR SIDE) Pin Description Circuit 1 RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY DG/LB 2 RIGHT REAR WHEEL SPEED SENSOR SIGNAL DG/OR Component Location - 63 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 5419 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front Wheel Speed Sensor: Diagrams Sensor-Wheel Speed-ABS-Left Front Component ID: 319 Component : SENSOR-WHEEL SPEED-ABS-LEFT FRONT Connector: Name : SENSOR-WHEEL SPEED-ABS-LEFT FRONT Color : BLACK # of pins : 2 Pin Description Circuit 1 LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY B9 20DG/LG 2 LEFT FRONT WHEEL SPEED SENSOR SIGNAL B8 20DG/TN Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 5422 Connector: Name : SENSOR-WHEEL SPEED-ABS-LEFT FRONT Color : # of pins : 2 Qualifier : (SENSOR SIDE) Pin Description Circuit 1 LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY DG/LG 2 LEFT FRONT WHEEL SPEED SENSOR SIGNAL DG/TN Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 5423 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 5424 Wheel Speed Sensor: Diagrams Sensor-Wheel Speed-ABS-Left Rear Component ID: 320 Component : SENSOR-WHEEL SPEED-ABS-LEFT REAR Connector: Name : SENSOR-WHEEL SPEED-ABS-LEFT REAR Color : BLACK # of pins : 2 Pin Description Circuit 1 LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY B4 20LG/BK 2 LEFT REAR WHEEL SPEED SENSOR SIGNAL B3 20LG/DB Component Location - 60 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 5425 Connector: Name : SENSOR-WHEEL SPEED-ABS-LEFT REAR Color : # of pins : 2 Qualifier : (SENSOR SIDE) Pin Description Circuit 1 LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY LG 2 LEFT REAR WHEEL SPEED SENSOR SIGNAL LG/DB Component Location - 60 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 5426 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 5427 Wheel Speed Sensor: Diagrams Sensor-Wheel Speed-ABS-Right Front Component ID: 321 Component : SENSOR-WHEEL SPEED-ABS-RIGHT FRONT Connector: Name : SENSOR-WHEEL SPEED-ABS-RIGHT FRONT Color : BLACK # of pins : 2 Pin Description Circuit 1 RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY B7 20WT 2 RIGHT FRONT WHEEL SPEED SENSOR SIGNAL B6 20WT/DB Component Location - 5 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 5428 Component Location - 6 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 5429 Connector: Name : SENSOR-WHEEL SPEED-ABS-RIGHT FRONT Color : # of pins : 2 Qualifier : (SENSOR SIDE) Pin Description Circuit 1 RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY WT 2 RIGHT FRONT WHEEL SPEED SENSOR SIGNAL WT/DB Component Location - 5 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 5430 Component Location - 6 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 5431 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 5432 Wheel Speed Sensor: Diagrams Sensor-Wheel Speed-ABS-Right Rear Component ID: 322 Component : SENSOR-WHEEL SPEED-ABS-RIGHT REAR Connector: Name : SENSOR-WHEEL SPEED-ABS-RIGHT REAR Color : BLACK # of pins : 2 Pin Description Circuit 1 RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY B2 20DG/LB 2 RIGHT REAR WHEEL SPEED SENSOR SIGNAL B1 20DG/OR 2 RIGHT REAR WHEEL SPEED SENSOR SIGNAL B1 20YL/DB Component Location - 63 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 5433 Connector: Name : SENSOR-WHEEL SPEED-ABS-RIGHT REAR Color : # of pins : 2 Qualifier : (SENSOR SIDE) Pin Description Circuit 1 RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY DG/LB 2 RIGHT REAR WHEEL SPEED SENSOR SIGNAL DG/OR Component Location - 63 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 5434 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Front Wheel Speed Wheel Speed Sensor: Description and Operation Front Wheel Speed Description DESCRIPTION The antilock brake system uses two-wire wheel speed sensors, known as active wheel speed sensors. The sensors use an electronic principle known as magnetoresistive to help increase performance and durability. The sensors convert wheel speed into a small digital signal. A Wheel Speed Sensor (WSS) is used at each wheel. A magnetic pole encoder serves as the trigger mechanism for each sensor. At each wheel of the vehicle there is one wheel speed sensor and one encoder. A front wheel speed sensor (3) is attached to a mounting boss on each front knuckle (4). The encoder is an integral part of the hub and bearing. WSS air gaps are not adjustable. Operation OPERATION The ABM sends 12 volts to power an Integrated Circuit (IC) in the sensor. The IC supplies a constant 7 mA power supply to the ABM. The relationship of the magnetic pole encoder to the permanent magnet in the sensor, signals the IC to enable a second 7 mA power supply. The output of the sensor, sent to the ABM, is a DC voltage signal with changing voltage and current levels. The ground for the IC and the current sense circuit is provided by the ABM. When a pole is properly aligned with the sensor, the voltage signal is approximately 0.8 volts and a constant 7 mA current is sent to the ABM. As the magnetic pole encoder rotates, the encoder shifts the magnetic field and the IC enables a second 7 mA current source. The ABM senses a voltage signal of approximately 1.6 volts and 14 mA. The ABM measures the amperage of the digital signal for each wheel. The resulting signal is interpreted by the ABM as the wheel speed. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Front Wheel Speed > Page 5437 Wheel Speed Sensor: Description and Operation Rear Wheel Speed Description DESCRIPTION The antilock brake system uses two-wire wheel speed sensors, known as active wheel speed sensors. The sensors use an electronic principle known as magnetoresistive to help increase performance and durability. The sensors convert wheel speed into a small digital signal. A Wheel Speed Sensor (WSS) is used at each wheel. A magnetic pole encoder serves as the trigger mechanism for each sensor. At each wheel of the vehicle there is one wheel speed sensor and one encoder. On all-wheel-drive vehicles, the rear wheel speed sensor head (1) is secured to the rear hub and bearing (2) by a spring-loaded clip on the rear of the assembly. The encoder is integral to the hub and bearing assembly. The encoder is serviced as part of the rear hub and bearing. On front-wheel-drive vehicles, the rear wheel speed sensor head (3) is mounted to the rear of the hub and bearing by a screw. The encoder is integral to the hub and bearing assembly. The encoder is are serviced as part of the rear hub and bearing. The WSS air gaps are not adjustable. Operation OPERATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Front Wheel Speed > Page 5438 The ABM sends 12 volts to power an Integrated Circuit (IC) in the sensor. The IC supplies a constant 7 mA power supply to the ABM. The relationship of the magnetic pole encoder to the permanent magnet in the sensor, signals the IC to enable a second 7 mA power supply. The output of the sensor, sent to the ABM, is a DC voltage signal with changing voltage and current levels. The ground for the IC and the current sense circuit is provided by the ABM. When a pole is properly aligned with the sensor, the voltage signal is approximately 0.8 volts and a constant 7 mA current is sent to the ABM. As the magnetic pole encoder rotates, the encoder shifts the magnetic field and the IC enables a second 7 mA current source. The ABM senses a voltage signal of approximately 1.6 volts and 14 mA. The ABM measures the amperage of the digital signal for each wheel. The resulting signal is interpreted by the ABM as the wheel speed. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Wheel Speed Sensor: Service and Repair Front Wheel Speed Removal REMOVAL NOTE: Refer to Warnings and Cautions. 1. Open the hood. 2. Disconnect the wheel speed sensor cable connector (2) from the wiring harness connector (3) on top of the frame rail (1) to the inside of the strut tower. 3. Raise and support the vehicle. 4. Remove the grommet (1) from the hole in the body (7) and pull the wheel speed sensor cable out of the hole. 5. Remove the speed sensor cable routing clip (2) from the outside frame rail (6). 6. Remove the screw fastening the cable routing clamp (3) to the outside frame rail (6). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 5441 7. Remove the screw (1) securing the wheel speed sensor routing bracket (2) to the brake flex hose bracket (5). 8. Remove the mounting screw (2) fastening the wheel speed sensor head (3) to the knuckle (4). Pull the sensor head out of the knuckle. NOTE: In the following step, the routing clip can be easily removed without damaging it by rotating it (with entire sensor) counterclockwise. 9. Remove the routing clip (1) securing wheel speed sensor cable to the knuckle (4). Remove the sensor from the vehicle. Installation INSTALLATION CAUTION: Failure to install speed sensor cables properly may result in contact with moving parts or an over extension of cables causing an open circuit. Be sure that cables are installed, routed, and clipped properly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 5442 1. Install the wheel speed sensor head (3) into the knuckle (4). Install the mounting screw (2) and tighten it to 12 Nm (106 in. lbs.). 2. Install the routing clip (1) securing the wheel speed sensor cable to the knuckle (4). 3. Position the wheel speed sensor routing bracket (2) on the brake flex hose bracket (5) and install the mounting screw (1). Tighten the mounting screw to 18 Nm (13 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 5443 4. Position the wheel speed sensor cable routing clamp (4) on the outside frame rail (6) and install the mounting screw (3). Tighten the mounting screw to 18 Nm (13 ft. lbs.). 5. Install the speed sensor cable routing clip (2) on the outside frame rail (6). 6. Insert the wheel speed sensor cable through the hole in the body (7) and install the grommet (1) in the hole. 7. Lower the vehicle. 8. Connect the wheel speed sensor cable connector (2) to the wiring harness connector (3) on top of the frame rail (1). 9. Perform the Diagnostic Verification Test and clear any faults. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 5444 Wheel Speed Sensor: Service and Repair Rear Wheel Speed All-Wheel-Drive ALL-WHEEL-DRIVE CAUTION: Failure to install speed sensor cables properly may result in contact with moving parts or an over extension of cables causing an open circuit. Be sure that cables are installed, routed, and clipped properly. NOTE: When installing the sensor head to the spring-loaded retainer on the hub and bearing, make sure the head is held snug in the retainer. If there is any play, the clip is deformed and the hub and bearing must be replaced. The retainer is not serviced separately. 1. Clip the wheel speed sensor head (1) (flat side to bearing rear face) into the spring-loaded retainer on the rear of the hub and bearing (2). 2. Position the wheel speed sensor (3) on the trailing link (2) and install the screw (4) securing it in place. Tighten the mounting screw to 18 Nm (13 ft. lbs.). 3. Position the wheel speed sensor (3) and install the routing clip (1) fastening the sensor to the trailing link (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 5445 4. Position the wheel speed sensor cable routing clamp (3) on the rear suspension crossmember (4) and install the mounting screw (1). Tighten the mounting screw to 18 Nm (13 ft. lbs.). 5. Install the speed sensor cable routing clip (3) on the outside frame rail (4). NOTE: When inserting the wheel speed sensor cable through the hole in the body, route the cable toward the shock tower to make it easier to grasp the cable to connect it to the body wiring harness connector in a later step. 6. Insert the wheel speed sensor cable (5) through the hole in the body (1) and install the grommet (2) in the hole. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 5446 7. Install the tire and wheel assembly (1). Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 8. Lower the vehicle. 9. Through the opening in the bottom of the quarter trim panel, connect the wheel speed sensor cable connector (2) to the body wiring harness connector (3). 10. If equipped, install the satellite receiver (1) or amplifier (2) to rear floor pan. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 5447 11. Install the rear floor pan silencer (1). 12. Install the cargo floor cover. 13. Perform the Diagnostic Verification Test and clear any faults. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests Installation - FWD FRONT-WHEEL-DRIVE 1. Install the wheel speed sensor head (3) into the rear of the hub and bearing (2). 2. Install the wheel speed sensor head mounting screw (1). Tighten the screw to 10 Nm (89 in. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 5448 3. Position the wheel speed sensor (3) on the trailing link (2) and install the screw (4) securing it in place. Tighten the mounting screw to 18 Nm (13 ft. lbs.). 4. Position the wheel speed sensor (3) and install the routing clip (1) fastening the sensor to the trailing link (2). 5. Position the wheel speed sensor cable routing clamp (3) on the rear suspension crossmember (4) and install the mounting screw (1). Tighten the mounting screw to 18 Nm (13 ft. lbs.). 6. Install the speed sensor cable routing clip (3) on the outside frame rail (4). NOTE: When inserting the wheel speed sensor cable through the hole in the body, route the cable toward the shock tower to make it easier to grasp the cable to connect it to the body wiring harness connector in a later step. 7. Insert the wheel speed sensor cable (5) through the hole in the body (1) and install the grommet (2) in the hole. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 5449 8. Install the tire and wheel assembly (1). Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 9. Lower the vehicle. 10. Through the opening in the bottom of the quarter trim panel, connect the wheel speed sensor cable connector (2) at the body wiring harness connector (3). 11. If equipped, install the satellite receiver (1) or amplifier (2) to rear floor pan. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 5450 12. Install the rear floor pan silencer (1). 13. Install the cargo floor cover. 14. Perform the Diagnostic Verification Test and clear any faults. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests All-Wheel-Drive ALL-WHEEL-DRIVE NOTE: Refer to Warnings and Cautions. 1. Remove the cargo floor cover. 2. Remove the rear floor pan silencer (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 5451 3. If equipped, remove the nuts mounting the satellite receiver (1) or amplifier (2) to rear floor pan. Move the component aside to allow access to the wheel speed sensor wiring connector through the opening in bottom of the quarter trim panel. 4. Through the opening in the bottom of the quarter trim panel, disconnect the wheel speed sensor cable connector (2) at the body wiring harness connector (3). 5. Raise and support the vehicle. 6. Remove the wheel mounting nuts (3), then the rear tire and wheel assembly (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 5452 7. Remove the grommet (2) from the hole in the body (1) and pull the wheel speed sensor cable out through the hole. 8. Remove the speed sensor cable routing clip (3) from the outside frame rail (4). 9. Remove the screw (1) fastening the cable routing clamp (3) to the rear suspension crossmember (4). 10. Remove the speed sensor cable routing clip (1) from the trailing link (2). 11. Remove the screw (4) fastening the cable routing clamp to the trailing link. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 5453 12. Unclip the wheel speed sensor head (1) from the spring-loaded retainer on the rear of the hub and bearing (2). Remove the sensor from the vehicle. Removal - FWD FRONT-WHEEL-DRIVE NOTE: Refer to Warnings and Cautions. 1. Remove the cargo floor cover. 2. Remove the rear floor pan silencer (1). 3. If equipped, remove the nuts mounting the satellite receiver (1) or amplifier (2) to rear floor pan. Move the component aside to allow access to the wheel speed sensor wiring connector through the opening in bottom of the quarter trim panel. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 5454 4. Through the opening in the bottom of the quarter trim panel, disconnect the wheel speed sensor cable connector (2) at the body wiring harness connector (3). 5. Raise and support the vehicle. 6. Remove the wheel mounting nuts (3), then the rear tire and wheel assembly (1). 7. Remove the grommet (2) from the hole in the body (1) and pull the wheel speed sensor cable out through the hole. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 5455 8. Remove the speed sensor cable routing clip (3) from the outside frame rail (4). 9. Remove the screw (1) fastening the cable routing clamp (3) to the rear suspension crossmember (4). 10. Remove the speed sensor cable routing clip (1) from the trailing link (2). 11. Remove the screw (4) fastening the cable routing clamp to the trailing link. 12. Remove the screw (1) fastening the wheel speed sensor head (3) in the rear of the hub and bearing (2). Remove the sensor from the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations Yaw Rate Sensor: Locations Component ID: 288 Component : SENSOR-DYNAMICS Connector: Name : SENSOR-DYNAMICS Color : BLACK # of pins : 6 Qualifier : (ESP) Pin Description Circuit 1 DYNAMICS SENSOR LOW DATA LINK D464 20WT/YL 2 DYNAMICS SENSOR HIGH DATA LINK D465 20WT/DB 3 DYNAMICS SENSOR SUPPLY G4 18VT/LB 4-5 DYNAMICS SENSOR GROUND G94 18VT/DB 6-- Component Location - 45 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 5459 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 5460 Yaw Rate Sensor: Diagrams Component ID: 288 Component : SENSOR-DYNAMICS Connector: Name : SENSOR-DYNAMICS Color : BLACK # of pins : 6 Qualifier : (ESP) Pin Description Circuit 1 DYNAMICS SENSOR LOW DATA LINK D464 20WT/YL 2 DYNAMICS SENSOR HIGH DATA LINK D465 20WT/DB 3 DYNAMICS SENSOR SUPPLY G4 18VT/LB 4-5 DYNAMICS SENSOR GROUND G94 18VT/DB 6-- Component Location - 45 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 5461 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 5462 Yaw Rate Sensor: Description and Operation DESCRIPTION The Yaw Rate and Lateral Acceleration Sensors are housed into one unit known as the Dynamics Sensor (1). The sensor is used to measure side-to-side (Lateral) motion and vehicle rotational sensing (how fast the vehicle is turning - Yaw). Yaw and Lateral Acceleration Sensors cannot be serviced separately. The entire Dynamics Sensor must be replaced when necessary. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Service and Repair > Removal Yaw Rate Sensor: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable from the battery post. 2. Remove the shifter housing center console. 3. Disconnect the wiring harness connector (3) at the dynamics sensor (1). 4. Remove the nuts (2) mounting the dynamics sensor to the floor pan tunnel (4). 5. Remove the dynamics sensor (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Service and Repair > Removal > Page 5465 Yaw Rate Sensor: Service and Repair Installation INSTALLATION 1. Install the dynamics sensor (1) over the studs mounted to the floor pan tunnel (4). 2. Install the two mounting nuts (2). Tighten the nuts to 9 Nm (80 in. lbs.). 3. Connect the wiring harness connector (3) to the dynamics sensor (1). 4. Install the shifter housing center console. 5. Connect the battery negative cable to the battery post. It is important that this be performed properly. 6. Perform the Verification Test and clear any faults. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder Ignition Switch Lock Cylinder: Service and Repair Key/Lock Cylinder Removal REMOVAL 1. Access and remove the Steering Column Control Module (SCCM) (3) from the steering column (2). 2. If equipped with Thatcham security (Export), remove the screws securing the cup (1) over the key cylinder. Remove the cup. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 5473 3. Remove the screw (1) fastening the SKREEM/WCM (2) to the lock cylinder housing (3). 4. Unhook the SKREEM/WCM (2) retainer fingers from the lock cylinder housing (3) and remove it. 5. Insert the key (2) and turn the key cylinder (3) to the RUN position. 6. Insert an appropriate tool into the slot (1) formed into the lock cylinder housing depressing the key cylinder retaining tab. 7. Pull the key cylinder and key straight out of the lock cylinder housing as one unit. 8. Using a Tamper-Proof Torx(R) Plus (five point) 30 bit, remove the two screws (1) fastening the lock cylinder housing (2) to the column. 9. Remove the lock cylinder housing from the steering column. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 5474 10. Remove the ignition module (2) mounting screw (1). 11. Pull the module (1) straight out and off the retaining tabs (2) located on the lock cylinder housing. Installation INSTALLATION NOTE: Ignition module must be installed prior to lock housing installation on column. Otherwise, the tilt lever will obstruct installation of ignition switch. 1. Ensure the ignition module is in the RUN position and the actuator shaft in the lock housing is in the RUN position. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 5475 2. Align the ignition module with the pin (3), actuator shaft and retaining tabs (2) located on the lock cylinder housing. Carefully install the module, snapping it into place over the retaining tabs. 3. Install the ignition module (2) mounting screw (1). Tighten the screw to 2 Nm (18 in. lbs.). NOTE: Ignition module needs to be installed on lock cylinder housing before housing installation to clear tilt lever. 4. Position the lock cylinder housing in the RUN position. 5. Align the lock cylinder housing (2) with the steering column. 6. Install the two screws (1) fastening the lock cylinder housing (2) to the column. Tighten the screws to 12 Nm (110 in. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 5476 7. Place the actuator in the lock cylinder housing to the RUN position (if not already there). 8. Insert the key into the key cylinder and turn the key cylinder to the RUN position. 9. Align the retaining tab on the key cylinder with the slot in the top of the lock cylinder housing. 10. Slide the key cylinder into the lock cylinder housing until the key cylinder retaining tab locks the cylinder into place. 11. Rotate the key back and forth (OFF to START), then remove and reinstall it, making sure the key cylinder and lock cylinder housing operate properly. 12. Slide the ring of the SKREEM/WCM (2) over the lock cylinder housing (3) and engage the retainer fingers in the recesses formed on the lock cylinder housing. 13. Install the screw (1) fastening the SKREEM/WCM (2) to the lock cylinder housing (3). Tighten the screw to 2.5 Nm (22 in. lbs.). 14. If equipped with Thatcham security (Export), install the cup (1) over the key cylinder and install the two mounting screws. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 5477 15. Install the Steering Column Control Module (SCCM) (3) and all components removed to access it. 16. Check operation of all steering column mounted components. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 5478 Ignition Switch Lock Cylinder: Service and Repair Housing-Lock Cylinder Removal REMOVAL 1. Access and remove the Steering Column Control Module (SCCM) (3) from the steering column (2). 2. If equipped with Thatcham security, remove the screws securing the cup (1) over the key cylinder. Remove the cup. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 5479 3. Remove the screw (1) fastening the SKREEM/WCM (2) to the lock cylinder housing (3). 4. Unhook the SKREEM/WCM (2) retainer fingers from the lock cylinder housing (3) and remove it. 5. Insert the key (2) and turn the key cylinder (3) to the RUN position. 6. Insert an appropriate tool into the slot (1) formed into the lock cylinder housing depressing the key cylinder retaining tab. 7. Pull the key cylinder and key straight out of the lock cylinder housing as one unit. 8. Using a Tamper-Proof Torx(R) Plus (five point) 30 bit, remove the two screws (1) fastening the lock cylinder housing (2) to the column. 9. Remove the lock cylinder housing from the steering column. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 5480 10. Remove the ignition module (2) mounting screw (1). 11. Pull the module (1) straight out and off the retaining tabs (2) located on the lock cylinder housing. Installation INSTALLATION NOTE: Ignition module must be installed prior to lock housing installation on column. Otherwise, the tilt lever will obstruct installation of ignition switch. 1. Ensure the ignition module is in the RUN position and the actuator shaft in the lock housing is in the RUN position. 2. Align the ignition module with the pin (3), actuator shaft and retaining tabs (2) located on the lock cylinder housing. Carefully install the module, snapping it into place over the retaining tabs. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 5481 3. Install the ignition module (2) mounting screw (1). Tighten the screw to 2 Nm (18 in. lbs.). NOTE: Ignition module needs to be installed on lock cylinder housing before housing installation to clear tilt lever. 4. Position the lock cylinder housing in the RUN position. 5. Align the lock cylinder housing (2) with the steering column. 6. Install the two screws (1) fastening the lock cylinder housing (2) to the column. Tighten the screws to 12 Nm (110 in. lbs.). 7. Place the actuator in the lock cylinder housing to the RUN position (if not already there). 8. Insert the key into the key cylinder and turn the key cylinder to the RUN position. 9. Align the retaining tab on the key cylinder with the slot in the top of the lock cylinder housing. 10. Slide the key cylinder into the lock cylinder housing until the key cylinder retaining tab locks the cylinder into place. 11. Rotate the key back and forth (OFF to START), then remove and reinstall it, making sure the key cylinder and lock cylinder housing operate Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 5482 properly. 12. Slide the ring of the SKREEM/WCM (2) over the lock cylinder housing (3) and engage the retainer fingers in the recesses formed on the lock cylinder housing. 13. Install the screw (1) fastening the SKREEM/WCM (2) to the lock cylinder housing (3). Tighten the screw to 2.5 Nm (22 in. lbs.). 14. If equipped with Thatcham security, install the cup (1) over the key cylinder and install the two mounting screws. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 5483 15. Install the Steering Column Control Module (SCCM) (3) and all components removed to access it. 16. Check operation of all steering column mounted components. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Neutral Safety Switch: Locations Component ID: 340 Component : SWITCH-CLUTCH INTERLOCK Connector: Name : SWITCH-CLUTCH INTERLOCK Color : BLACK # of pins : 3 Qualifier : (MTX) Pin Description Circuit 1 CLUTCH UPSTOP SWITCH SIGNAL T26 20DG/OR 2 GROUND Z925 20BK/OR 2 GROUND Z961 20BK/YL 3 CLUTCH INTERLOCK SIGNAL T141 20YL/RD Component Location - 44 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 5487 Component Location - 47 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 5488 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 5489 Neutral Safety Switch: Diagrams Component ID: 340 Component : SWITCH-CLUTCH INTERLOCK Connector: Name : SWITCH-CLUTCH INTERLOCK Color : BLACK # of pins : 3 Qualifier : (MTX) Pin Description Circuit 1 CLUTCH UPSTOP SWITCH SIGNAL T26 20DG/OR 2 GROUND Z925 20BK/OR 2 GROUND Z961 20BK/YL 3 CLUTCH INTERLOCK SIGNAL T141 20YL/RD Component Location - 44 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 5490 Component Location - 47 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 5491 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and Operation > Battery Cables - Description Battery Cable: Description and Operation Battery Cables - Description DESCRIPTION The battery cables are large gauge, stranded copper wires sheathed within a heavy plastic or synthetic rubber insulating jacket. The wire used in the battery cables combines excellent flexibility and reliability with high electrical current carrying capacity. The battery cables feature a clamping type female battery terminal made of stamped sheet metal that is die cast onto one end of the battery cable wire. A pinch-bolt and nut are installed at the open end of the female battery terminal clamp. Large eyelet type terminals are crimped onto the opposite end of the battery cable wire and then soldered. The battery positive cable wires feature a larger female battery terminal clamp to allow connection to the larger battery positive terminal post. The battery negative cable wires have a smaller female battery terminal clamp. Both the battery positive and negative cables are available for service replacement only as a unit with the battery wire harness, which may include portions of the wiring circuits for the generator and other components on some vehicles. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and Operation > Battery Cables - Description > Page 5497 Battery Cable: Description and Operation Battery Cables - Operation OPERATION The battery cables connect the battery terminal posts to the vehicle electrical system. These cables also provide a path back to the battery for electrical current generated by the charging system for restoring the voltage potential of the battery. The female battery terminal clamps on the ends of the battery cable wires provide a strong and reliable connection of the battery cable to the battery terminal posts. The terminal pinch bolts allow the female terminal clamps to be tightened around the male terminal posts on the top of the battery. The eyelet terminals secured to the opposite ends of the battery cable wires from the female battery terminal clamps provide secure and reliable connection of the battery cables to the vehicle electrical system. One wire has an eyelet terminal that connects the battery positive cable to the B(+) terminal stud of the Totally Integrated Power Module (TIPM), and the other wire has an eyelet terminal that connects the battery positive cable to the B(+) terminal stud of the engine starter motor solenoid. The battery negative cable terminal clamp has one wire as an eyelet terminal that connects the battery negative cable to the vehicle powertrain through a ground connection, typically on the engine cylinder block. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and Operation > Page 5498 Battery Cable: Testing and Inspection BATTERY CABLES A voltage drop test will determine if there is excessive resistance in the battery cable terminal connections or the battery cable. If excessive resistance is found in the battery cable connections, the connection point should be disassembled, cleaned of all corrosion or foreign material, then reassembled. Following reassembly, check the voltage drop for the battery cable connection and the battery cable again to confirm repair. When performing the voltage drop test, it is important to remember that the voltage drop is giving an indication of the resistance between the two points at which the voltmeter probes are attached. EXAMPLE: When testing the resistance of the battery positive cable, touch the voltmeter leads to the battery positive cable terminal clamp and to the battery positive cable eyelet terminal at the starter solenoid B(+) terminal stud. If you probe the battery positive terminal post and the battery positive cable eyelet terminal at the starter solenoid B(+) terminal stud, you are reading the combined voltage drop in the battery positive cable terminal clamp-to-terminal post connection and the battery positive cable. VOLTAGE DROP TEST The following operation will require a voltmeter accurate to 1/10 (0.10) volt. Before performing this test, be certain that the following procedures are accomplished: - The battery is fully-charged and load tested. - Fully engage the parking brake. - If the vehicle is equipped with an automatic transmission, place the gearshift selector lever in the Park position. If the vehicle is equipped with a manual transmission, place the gearshift selector lever in the Neutral position and block the clutch pedal in the fully depressed position. - Verify that all lamps and accessories are turned off. - To prevent the engine from starting, remove the Automatic Shut Down (ASD) relay. The ASD relay can be found in the Fuse Block located in the left front bumper fascia. See the fuse and relay layout label affixed to the underside of the Fuse Block cover for ASD relay identification and location. 1. Connect the positive lead of the voltmeter (1) to the battery (2) negative terminal post. Connect the negative lead of the voltmeter (1) to the battery (2) negative cable terminal clamp. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor connection between the battery negative cable terminal clamp and the battery negative terminal post. 2. Connect the positive lead of the voltmeter (1) to the battery (2) positive terminal post. Connect the negative lead of the voltmeter (1) to the battery (2) positive cable terminal clamp. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor connection between the battery positive cable terminal clamp and the battery positive terminal post. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and Operation > Page 5499 3. Connect the voltmeter (2) to measure between the battery positive cable terminal clamp (1) and the starter solenoid B(+) terminal stud (3). Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2 volt, clean and tighten the battery positive cable eyelet terminal connection at the starter solenoid B(+) terminal stud. Repeat the test. If the reading is still above 0.2 volt, replace the faulty battery positive cable. 4. Connect the voltmeter (1) to measure between the battery (2) negative cable terminal clamp and a good clean ground on the engine block (3). Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2 volt, clean and tighten the battery negative cable eyelet terminal connection to the engine block. Repeat the test. If the reading is still above 0.2 volt, replace the faulty battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Battery Cables - Removal Battery Cable: Service and Repair Battery Cables - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Rotate the two retaining clips (3) and remove the air cleaner fresh air duct (2). WARNING: The battery negative and positive cable polarity are different from the gasoline engine equipped vehicles to the diesel engine equipped vehicles. Please note the location of the positive and negative cables prior to service of the battery or related components. NOTE: Diesel battery shown, gasoline battery similar. 3. Remove the nut (2) securing the Totally Integrated Power Module (TIPM) cable (1) to the battery clamp stud (5). 4. Disconnect and isolate the battery negative cable then the positive cable (3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Battery Cables - Removal > Page 5502 5. Remove the nut (1) securing the negative cable (2) to the body ground stud. 6. Remove the battery cable from the B+ terminal of the generator. 7. Remove the battery cable from the B+ terminal of the starter motor. 8. One at a time, trace the battery cable retaining pushpins, fasteners and routing clips until the cables are free from the vehicle. 9. Remove the battery cables from the engine compartment. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Battery Cables - Removal > Page 5503 Battery Cable: Service and Repair Battery Cables - Installation INSTALLATION 1. Position the battery cables in the engine compartment. 2. One at a time, install the battery cable retaining pushpins, fasteners and routing clips until the cables are installed exactly where they were in the vehicle. 3. Connect the battery cable to the B+ terminal of the starter motor. Tighten the cable nut to 13 Nm (115 in. lbs.). 4. Connect the battery cable to the B+ terminal of the generator. Tighten the cable nut to 14 Nm (125 in. lbs.). 5. Install the nut (1) securing the negative cable (2) to the body ground stud. Tighten the cable nut to 12 Nm (9 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Battery Cables - Removal > Page 5504 WARNING: The battery negative and positive cable polarity are different from the gasoline engine equipped vehicles to the diesel engine equipped vehicles. Please note the location of the positive and negative cables prior to service of the battery or related components. NOTE: Diesel battery shown, gasoline battery similar. 6. Connect the battery positive cable then the negative cable (3). 7. Tighten the cable clamp nuts to 5 Nm (45 in. lbs.). 8. Install the nut (2) securing the Totally Integrated Power Module (TIPM) cable (1) to the battery clamp stud (5). 9. Install the air cleaner fresh air duct (2) and secure in place by rotating the two retaining clips (3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Description and Operation Battery Tray: Description and Operation DESCRIPTION The battery is placed and secured in a plastic battery tray (3). The battery tray is located in the left front side of the vehicle and is secured in place by one nut (2) and four bolts (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Retainer - Removal Battery Tray: Service and Repair Battery Retainer - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Rotate the two retaining clips (3) and remove the air cleaner fresh air duct (2). 3. Remove the battery hold down retaining bolt (1). 4. Remove the battery hold down (2) from the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Retainer - Removal > Page 5510 Battery Tray: Service and Repair Battery Retainer - Installation INSTALLATION 1. Install the battery hold down (2) into the vehicle. 2. Install the battery hold down retaining bolt (1). Tighten the bolt to 7 Nm (62 in. lbs.). 3. Install the air cleaner fresh air duct (2) and secure in place by rotating the two retaining clips (3). 4. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Retainer - Removal > Page 5511 Battery Tray: Service and Repair Battery Tray - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. On diesel engine equipped vehicles disconnect the vacuum connector (3) and electrical connector (1) from the diesel vacuum valve (2). 3. On diesel engine equipped vehicles lift the diesel vacuum valve bracket (1) up disengaging the mounting tabs from the receptacles (2) in the battery tray. 4. Remove the battery. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Retainer - Removal > Page 5512 5. Remove the four bolts (1) and one nut (2) securing the battery tray (3) to the left frame rail (4). 6. Lift the battery tray out of the engine compartment and remove from the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Retainer - Removal > Page 5513 Battery Tray: Service and Repair Battery Tray - Installation INSTALLATION 1. Place the battery tray (3) into the engine compartment over the left frame rail (4). 2. Install the one nut (2) and four bolts (1) securing the battery tray (3) to the frame rail (4). 3. Tighten the nut to 10.5 Nm (93 in. lbs.). 4. Tighten the bolts to 10.5 Nm (93 in. lbs.). 5. Install the battery. 6. On diesel engine equipped vehicles install the diesel vacuum valve. Push the bracket (1) down until the mounting tabs are completely seated into the receptacles (2) in the battery tray. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Retainer - Removal > Page 5514 7. On diesel engine equipped vehicles connect the vacuum connector (3) and electrical connector (1) to the diesel vacuum valve (2). 8. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Locations Alternator: Locations Component ID: 97 Component : GENERATOR Connector: Name : GENERATOR Color : BLACK # of pins : 2 Qualifier : (DIESEL) Pin Description Circuit 1 CHARGE INDICATOR SIGNAL G329 20VT/OR 2 GEN OUTPUT SIGNAL K92 20BR/YL Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Locations > Page 5519 Component Location - 18 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Locations > Page 5520 Connector: Name : GENERATOR Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 GEN FIELD CONTROL K20 20BR/GY 2 GEN SENSE A804 20RD/GY Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Locations > Page 5521 Component Location - 18 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Locations > Page 5522 Connector: Name : GENERATOR-EYELET Color : # of pins : 1 Pin Description Circuit 1 B(+) A801 4RD/GY Pin Description Circuit 1 B(+) A801 6RD/GY Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Locations > Page 5523 Component Location - 14 Component Location - 18 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Locations > Page 5524 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions Alternator: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: Provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5527 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5528 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5529 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5530 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5531 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5532 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5533 5. Release the Secondary Terminal Lock, if required (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5534 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5535 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5536 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5537 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5538 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5539 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5540 Alternator: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5541 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5542 STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5543 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5544 Alternator: Connector Views Component ID: 97 Component : GENERATOR Connector: Name : GENERATOR Color : BLACK # of pins : 2 Qualifier : (DIESEL) Pin Description Circuit 1 CHARGE INDICATOR SIGNAL G329 20VT/OR 2 GEN OUTPUT SIGNAL K92 20BR/YL Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5545 Component Location - 18 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5546 Connector: Name : GENERATOR Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 GEN FIELD CONTROL K20 20BR/GY 2 GEN SENSE A804 20RD/GY Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5547 Component Location - 18 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5548 Connector: Name : GENERATOR-EYELET Color : # of pins : 1 Pin Description Circuit 1 B(+) A801 4RD/GY Pin Description Circuit 1 B(+) A801 6RD/GY Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5549 Component Location - 14 Component Location - 18 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5550 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Description and Operation > Description Alternator: Description and Operation Description DESCRIPTION The generator is belt-driven by the engine. It is serviced only as a complete assembly. If the generator fails for any reason, the entire assembly must be replaced. The generator produces DC voltage. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Description and Operation > Description > Page 5553 Alternator: Description and Operation Operation OPERATION As the energized rotor begins to rotate within the generator, the spinning magnetic field induces a current into the windings of the stator coil. The Y type stator winding connections deliver the induced AC current to 3 positive and 3 negative diodes for rectification. From the diodes, rectified DC current is delivered to the vehicles electrical system through the generator, battery, and ground terminals. Noise emitting from the generator may be caused by: - Worn, loose or defective bearings - Loose or defective drive pulley - Incorrect, worn, damaged or misadjusted drive belt - Loose mounting bolts - Misaligned drive pulley - Defective stator or diode - Damaged internal fins Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Removal Alternator: Service and Repair Removal 2.0/2.4L 1. Disconnect the negative battery cable. 2. Raise and support vehicle. 3. Remove the right front wheel. 4. Remove the underbody air dam. 5. Remove the accessory drive splash shield. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Removal > Page 5556 6. Remove the accessory drive idler pulley. 7. Loosen the lower mounting bolt. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Removal > Page 5557 8. Loosen the A/C compressor and relocate, pull down and to outboard side of vehicle to make room to remove generator. 9. Unplug field circuit from generator. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Removal > Page 5558 10. Remove the B+ terminal nut and wire. 11. Remove the upper mounting bolt. 12. Remove the generator lower mounting bolt. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Removal > Page 5559 13. Relocate the battery terminal (1) to the other side of the A/C line (2) for removal of the generator. 14. Rotate generator pulley down. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Removal > Page 5560 15. Slide generator down and out of vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Removal > Page 5561 Alternator: Service and Repair Installation 2.0/2.4L 1. Move A/C compressor to the side to install generator. 2. Rotate generator and set in place. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Removal > Page 5562 Make sure battery terminal (1) is in front of A/C line (2). 3. Loose install lower mounting bolt. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Removal > Page 5563 4. Loose install upper mounting bolt. 5. Tighten bolts to GAS 54 Nm (40 ft. lbs.) DIESEL 26 Nm (19 ft. lbs.). 6. Install the B+ terminal nut and wire and tighten to GAS & DIESEL 10 Nm (88.5 in. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Removal > Page 5564 7. Plug in the field circuit to the generator. 8. Install idler pulley and tighten bolt. 9. Install the accessory drive belt. 10. Install splash shield. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Removal > Page 5565 11. Install lower air dam. 12. Lower vehicle. 13. Connect the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder Ignition Switch Lock Cylinder: Service and Repair Key/Lock Cylinder Removal REMOVAL 1. Access and remove the Steering Column Control Module (SCCM) (3) from the steering column (2). 2. If equipped with Thatcham security (Export), remove the screws securing the cup (1) over the key cylinder. Remove the cup. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 5572 3. Remove the screw (1) fastening the SKREEM/WCM (2) to the lock cylinder housing (3). 4. Unhook the SKREEM/WCM (2) retainer fingers from the lock cylinder housing (3) and remove it. 5. Insert the key (2) and turn the key cylinder (3) to the RUN position. 6. Insert an appropriate tool into the slot (1) formed into the lock cylinder housing depressing the key cylinder retaining tab. 7. Pull the key cylinder and key straight out of the lock cylinder housing as one unit. 8. Using a Tamper-Proof Torx(R) Plus (five point) 30 bit, remove the two screws (1) fastening the lock cylinder housing (2) to the column. 9. Remove the lock cylinder housing from the steering column. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 5573 10. Remove the ignition module (2) mounting screw (1). 11. Pull the module (1) straight out and off the retaining tabs (2) located on the lock cylinder housing. Installation INSTALLATION NOTE: Ignition module must be installed prior to lock housing installation on column. Otherwise, the tilt lever will obstruct installation of ignition switch. 1. Ensure the ignition module is in the RUN position and the actuator shaft in the lock housing is in the RUN position. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 5574 2. Align the ignition module with the pin (3), actuator shaft and retaining tabs (2) located on the lock cylinder housing. Carefully install the module, snapping it into place over the retaining tabs. 3. Install the ignition module (2) mounting screw (1). Tighten the screw to 2 Nm (18 in. lbs.). NOTE: Ignition module needs to be installed on lock cylinder housing before housing installation to clear tilt lever. 4. Position the lock cylinder housing in the RUN position. 5. Align the lock cylinder housing (2) with the steering column. 6. Install the two screws (1) fastening the lock cylinder housing (2) to the column. Tighten the screws to 12 Nm (110 in. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 5575 7. Place the actuator in the lock cylinder housing to the RUN position (if not already there). 8. Insert the key into the key cylinder and turn the key cylinder to the RUN position. 9. Align the retaining tab on the key cylinder with the slot in the top of the lock cylinder housing. 10. Slide the key cylinder into the lock cylinder housing until the key cylinder retaining tab locks the cylinder into place. 11. Rotate the key back and forth (OFF to START), then remove and reinstall it, making sure the key cylinder and lock cylinder housing operate properly. 12. Slide the ring of the SKREEM/WCM (2) over the lock cylinder housing (3) and engage the retainer fingers in the recesses formed on the lock cylinder housing. 13. Install the screw (1) fastening the SKREEM/WCM (2) to the lock cylinder housing (3). Tighten the screw to 2.5 Nm (22 in. lbs.). 14. If equipped with Thatcham security (Export), install the cup (1) over the key cylinder and install the two mounting screws. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 5576 15. Install the Steering Column Control Module (SCCM) (3) and all components removed to access it. 16. Check operation of all steering column mounted components. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 5577 Ignition Switch Lock Cylinder: Service and Repair Housing-Lock Cylinder Removal REMOVAL 1. Access and remove the Steering Column Control Module (SCCM) (3) from the steering column (2). 2. If equipped with Thatcham security, remove the screws securing the cup (1) over the key cylinder. Remove the cup. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 5578 3. Remove the screw (1) fastening the SKREEM/WCM (2) to the lock cylinder housing (3). 4. Unhook the SKREEM/WCM (2) retainer fingers from the lock cylinder housing (3) and remove it. 5. Insert the key (2) and turn the key cylinder (3) to the RUN position. 6. Insert an appropriate tool into the slot (1) formed into the lock cylinder housing depressing the key cylinder retaining tab. 7. Pull the key cylinder and key straight out of the lock cylinder housing as one unit. 8. Using a Tamper-Proof Torx(R) Plus (five point) 30 bit, remove the two screws (1) fastening the lock cylinder housing (2) to the column. 9. Remove the lock cylinder housing from the steering column. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 5579 10. Remove the ignition module (2) mounting screw (1). 11. Pull the module (1) straight out and off the retaining tabs (2) located on the lock cylinder housing. Installation INSTALLATION NOTE: Ignition module must be installed prior to lock housing installation on column. Otherwise, the tilt lever will obstruct installation of ignition switch. 1. Ensure the ignition module is in the RUN position and the actuator shaft in the lock housing is in the RUN position. 2. Align the ignition module with the pin (3), actuator shaft and retaining tabs (2) located on the lock cylinder housing. Carefully install the module, snapping it into place over the retaining tabs. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 5580 3. Install the ignition module (2) mounting screw (1). Tighten the screw to 2 Nm (18 in. lbs.). NOTE: Ignition module needs to be installed on lock cylinder housing before housing installation to clear tilt lever. 4. Position the lock cylinder housing in the RUN position. 5. Align the lock cylinder housing (2) with the steering column. 6. Install the two screws (1) fastening the lock cylinder housing (2) to the column. Tighten the screws to 12 Nm (110 in. lbs.). 7. Place the actuator in the lock cylinder housing to the RUN position (if not already there). 8. Insert the key into the key cylinder and turn the key cylinder to the RUN position. 9. Align the retaining tab on the key cylinder with the slot in the top of the lock cylinder housing. 10. Slide the key cylinder into the lock cylinder housing until the key cylinder retaining tab locks the cylinder into place. 11. Rotate the key back and forth (OFF to START), then remove and reinstall it, making sure the key cylinder and lock cylinder housing operate Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 5581 properly. 12. Slide the ring of the SKREEM/WCM (2) over the lock cylinder housing (3) and engage the retainer fingers in the recesses formed on the lock cylinder housing. 13. Install the screw (1) fastening the SKREEM/WCM (2) to the lock cylinder housing (3). Tighten the screw to 2.5 Nm (22 in. lbs.). 14. If equipped with Thatcham security, install the cup (1) over the key cylinder and install the two mounting screws. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 5582 15. Install the Steering Column Control Module (SCCM) (3) and all components removed to access it. 16. Check operation of all steering column mounted components. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > System Information > Technical Service Bulletins > Customer Interest for Keyless Starting System: > 08-018-07 > Jun > 07 > Remote Start System - RKE Inop/Alarm Sounds Keyless Starting System: Customer Interest Remote Start System - RKE Inop/Alarm Sounds NUMBER: 08-018-07 GROUP: Electrical DATE: June 23, 2007 SUBJECT: Mopar Remote Start System - RKE - Intermittent Operation Or Alarm May Sound OVERVIEW: This bulletin involves the installation of a Mopar Remote Start System - Service Repair Kit. MODELS: 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) 2007 (HB/HG) Durango/Aspen 2007 (JK) Wrangler 2008 (J527) Sebring Convertible 2007 (JS) Sebring 2007-2008 (JS) Avenger 2007 (KA) Nitro 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to vehicles installed with a Mopar Remote Start Installation Kit. SYMPTOM/CONDITION: On vehicles that have had a Mopar Remote Start installation Kit installed by a dealer, the customer may experience one or more of the following conditions: A). ON ALL VEHICLES: An intermittent operation of the Remote Keyless Entry (RKE) system. At times, the RKE system may not function as designed. This may include intermittent operation of: lock/unlock mode, remote start mode, or panic mode. The vehicle may be operated manually without issue using the ignition key to open or lock the door, and to start the vehicle. B). ON RAM TRUCK AND DURANGO/ASPEN VEHICLES ONLY: The vehicle alarm may sound when the RKE system is activated by use of the key FOB. Deactivation of the vehicle alarm occurs when the vehicle engine is started using the ignition switch and key. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > System Information > Technical Service Bulletins > Customer Interest for Keyless Starting System: > 08-018-07 > Jun > 07 > Remote Start System - RKE Inop/Alarm Sounds > Page 5591 The above condition(s) may be present ONLY if one of the following specific kit part numbers for the Mopar Remote Start Installation Kit had been installed previously on the suspect vehicle. DIAGNOSIS: If the customer has experienced the above condition, and the vehicle has had a Mopar Remote Start Installation Kit installed, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Install the Remote Start Service Repair Kit. Refer to the detailed instructions included with the repair kit. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > System Information > Technical Service Bulletins > Customer Interest for Keyless Starting System: > 18-018-07 > Jun > 07 > Remote Starting System - RKE, Int. Operation/Alarm Keyless Starting System: Customer Interest Remote Starting System - RKE, Int. Operation/Alarm NUMBER: 18-018-07 GROUP: Electrical DATE: June 23, 2007 SUBJECT: Mopar Remote Start System - RKE - Intermittent Operation Or Alarm May Sound OVERVIEW: This bulletin involves the installation of a Mopar Remote Start System - Service Repair Kit. MODELS: 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) 2007 (HB/HG) Durango/Aspen 2007 (JK) Wrangler 2008 (J527) Sebring Convertible 2007 (JS) Sebring 2007-2008 (JS) Avenger 2007 (KA) Nitro 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to vehicles installed with a Mopar Remote Start Installation Kit. SYMPTOM/CONDITION: On vehicles that have had a Mopar Remote Start installation Kit installed by a dealer, the customer may experience one or more of the following conditions: A). ON ALL VEHICLES: An intermittent operation of the Remote Keyless Entry (RKE) system. At times, the RKE system may not function as designed. This may include intermittent operation of: lock/unlock mode, remote start mode, or panic mode. The vehicle may be operated manually without issue using the ignition key to open or lock the door, and to start the vehicle. B). ON RAM TRUCK AND DURANGO/ASPEN VEHICLES ONLY: The vehicle alarm may sound when the RKE system is activated by use of the key FOB. Deactivation of the vehicle alarm occurs when the vehicle engine is started using the ignition switch and key. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > System Information > Technical Service Bulletins > Customer Interest for Keyless Starting System: > 18-018-07 > Jun > 07 > Remote Starting System - RKE, Int. Operation/Alarm > Page 5596 The above condition(s) may be present ONLY if one of the following specific kit part numbers for the Mopar Remote Start Installation Kit had been installed previously on the suspect vehicle. DIAGNOSIS: If the customer has experienced the above condition, and the vehicle has had a Mopar Remote Start Installation Kit installed, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Install the Remote Start Service Repair Kit. Refer to the detailed instructions included with the repair kit. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > 08-018-07 > Jun > 07 > Remote Start System - RKE Inop/Alarm Sounds Keyless Starting System: All Technical Service Bulletins Remote Start System - RKE Inop/Alarm Sounds NUMBER: 08-018-07 GROUP: Electrical DATE: June 23, 2007 SUBJECT: Mopar Remote Start System - RKE - Intermittent Operation Or Alarm May Sound OVERVIEW: This bulletin involves the installation of a Mopar Remote Start System - Service Repair Kit. MODELS: 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) 2007 (HB/HG) Durango/Aspen 2007 (JK) Wrangler 2008 (J527) Sebring Convertible 2007 (JS) Sebring 2007-2008 (JS) Avenger 2007 (KA) Nitro 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to vehicles installed with a Mopar Remote Start Installation Kit. SYMPTOM/CONDITION: On vehicles that have had a Mopar Remote Start installation Kit installed by a dealer, the customer may experience one or more of the following conditions: A). ON ALL VEHICLES: An intermittent operation of the Remote Keyless Entry (RKE) system. At times, the RKE system may not function as designed. This may include intermittent operation of: lock/unlock mode, remote start mode, or panic mode. The vehicle may be operated manually without issue using the ignition key to open or lock the door, and to start the vehicle. B). ON RAM TRUCK AND DURANGO/ASPEN VEHICLES ONLY: The vehicle alarm may sound when the RKE system is activated by use of the key FOB. Deactivation of the vehicle alarm occurs when the vehicle engine is started using the ignition switch and key. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > 08-018-07 > Jun > 07 > Remote Start System - RKE Inop/Alarm Sounds > Page 5602 The above condition(s) may be present ONLY if one of the following specific kit part numbers for the Mopar Remote Start Installation Kit had been installed previously on the suspect vehicle. DIAGNOSIS: If the customer has experienced the above condition, and the vehicle has had a Mopar Remote Start Installation Kit installed, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Install the Remote Start Service Repair Kit. Refer to the detailed instructions included with the repair kit. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > 18-018-07 > Jun > 07 > Remote Starting System - RKE, Int. Operation/Alarm Keyless Starting System: All Technical Service Bulletins Remote Starting System - RKE, Int. Operation/Alarm NUMBER: 18-018-07 GROUP: Electrical DATE: June 23, 2007 SUBJECT: Mopar Remote Start System - RKE - Intermittent Operation Or Alarm May Sound OVERVIEW: This bulletin involves the installation of a Mopar Remote Start System - Service Repair Kit. MODELS: 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) 2007 (HB/HG) Durango/Aspen 2007 (JK) Wrangler 2008 (J527) Sebring Convertible 2007 (JS) Sebring 2007-2008 (JS) Avenger 2007 (KA) Nitro 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to vehicles installed with a Mopar Remote Start Installation Kit. SYMPTOM/CONDITION: On vehicles that have had a Mopar Remote Start installation Kit installed by a dealer, the customer may experience one or more of the following conditions: A). ON ALL VEHICLES: An intermittent operation of the Remote Keyless Entry (RKE) system. At times, the RKE system may not function as designed. This may include intermittent operation of: lock/unlock mode, remote start mode, or panic mode. The vehicle may be operated manually without issue using the ignition key to open or lock the door, and to start the vehicle. B). ON RAM TRUCK AND DURANGO/ASPEN VEHICLES ONLY: The vehicle alarm may sound when the RKE system is activated by use of the key FOB. Deactivation of the vehicle alarm occurs when the vehicle engine is started using the ignition switch and key. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > 18-018-07 > Jun > 07 > Remote Starting System - RKE, Int. Operation/Alarm > Page 5607 The above condition(s) may be present ONLY if one of the following specific kit part numbers for the Mopar Remote Start Installation Kit had been installed previously on the suspect vehicle. DIAGNOSIS: If the customer has experienced the above condition, and the vehicle has had a Mopar Remote Start Installation Kit installed, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Install the Remote Start Service Repair Kit. Refer to the detailed instructions included with the repair kit. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > Page 5608 Keyless Starting System: By Symptom Technical Service Bulletin # 18-018-07 Date: 070623 Remote Starting System - RKE, Int. Operation/Alarm NUMBER: 18-018-07 GROUP: Electrical DATE: June 23, 2007 SUBJECT: Mopar Remote Start System - RKE - Intermittent Operation Or Alarm May Sound OVERVIEW: This bulletin involves the installation of a Mopar Remote Start System - Service Repair Kit. MODELS: 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) 2007 (HB/HG) Durango/Aspen 2007 (JK) Wrangler 2008 (J527) Sebring Convertible 2007 (JS) Sebring 2007-2008 (JS) Avenger 2007 (KA) Nitro 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to vehicles installed with a Mopar Remote Start Installation Kit. SYMPTOM/CONDITION: On vehicles that have had a Mopar Remote Start installation Kit installed by a dealer, the customer may experience one or more of the following conditions: A). ON ALL VEHICLES: An intermittent operation of the Remote Keyless Entry (RKE) system. At times, the RKE system may not function as designed. This may include intermittent operation of: lock/unlock mode, remote start mode, or panic mode. The vehicle may be operated manually without issue using the ignition key to open or lock the door, and to start the vehicle. B). ON RAM TRUCK AND DURANGO/ASPEN VEHICLES ONLY: The vehicle alarm may sound when the RKE system is activated by use of the key FOB. Deactivation of the vehicle alarm occurs when the vehicle engine is started using the ignition switch and key. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > Page 5609 The above condition(s) may be present ONLY if one of the following specific kit part numbers for the Mopar Remote Start Installation Kit had been installed previously on the suspect vehicle. DIAGNOSIS: If the customer has experienced the above condition, and the vehicle has had a Mopar Remote Start Installation Kit installed, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Install the Remote Start Service Repair Kit. Refer to the detailed instructions included with the repair kit. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 08-018-07 Date: 070623 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > Page 5610 Remote Start System - RKE Inop/Alarm Sounds NUMBER: 08-018-07 GROUP: Electrical DATE: June 23, 2007 SUBJECT: Mopar Remote Start System - RKE - Intermittent Operation Or Alarm May Sound OVERVIEW: This bulletin involves the installation of a Mopar Remote Start System - Service Repair Kit. MODELS: 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) 2007 (HB/HG) Durango/Aspen 2007 (JK) Wrangler 2008 (J527) Sebring Convertible 2007 (JS) Sebring 2007-2008 (JS) Avenger 2007 (KA) Nitro 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to vehicles installed with a Mopar Remote Start Installation Kit. SYMPTOM/CONDITION: On vehicles that have had a Mopar Remote Start installation Kit installed by a dealer, the customer may experience one or more of the following conditions: A). ON ALL VEHICLES: An intermittent operation of the Remote Keyless Entry (RKE) system. At times, the RKE system may not function as designed. This may include intermittent operation of: lock/unlock mode, remote start mode, or panic mode. The vehicle may be operated manually without issue using the ignition key to open or lock the door, and to start the vehicle. B). ON RAM TRUCK AND DURANGO/ASPEN VEHICLES ONLY: The vehicle alarm may sound when the RKE system is activated by use of the key FOB. Deactivation of the vehicle alarm occurs when the vehicle engine is started using the ignition switch and key. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > Page 5611 The above condition(s) may be present ONLY if one of the following specific kit part numbers for the Mopar Remote Start Installation Kit had been installed previously on the suspect vehicle. DIAGNOSIS: If the customer has experienced the above condition, and the vehicle has had a Mopar Remote Start Installation Kit installed, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Install the Remote Start Service Repair Kit. Refer to the detailed instructions included with the repair kit. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 18-018-07 Date: 070623 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > Page 5612 Remote Starting System - RKE, Int. Operation/Alarm NUMBER: 18-018-07 GROUP: Electrical DATE: June 23, 2007 SUBJECT: Mopar Remote Start System - RKE - Intermittent Operation Or Alarm May Sound OVERVIEW: This bulletin involves the installation of a Mopar Remote Start System - Service Repair Kit. MODELS: 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) 2007 (HB/HG) Durango/Aspen 2007 (JK) Wrangler 2008 (J527) Sebring Convertible 2007 (JS) Sebring 2007-2008 (JS) Avenger 2007 (KA) Nitro 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to vehicles installed with a Mopar Remote Start Installation Kit. SYMPTOM/CONDITION: On vehicles that have had a Mopar Remote Start installation Kit installed by a dealer, the customer may experience one or more of the following conditions: A). ON ALL VEHICLES: An intermittent operation of the Remote Keyless Entry (RKE) system. At times, the RKE system may not function as designed. This may include intermittent operation of: lock/unlock mode, remote start mode, or panic mode. The vehicle may be operated manually without issue using the ignition key to open or lock the door, and to start the vehicle. B). ON RAM TRUCK AND DURANGO/ASPEN VEHICLES ONLY: The vehicle alarm may sound when the RKE system is activated by use of the key FOB. Deactivation of the vehicle alarm occurs when the vehicle engine is started using the ignition switch and key. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > Page 5613 The above condition(s) may be present ONLY if one of the following specific kit part numbers for the Mopar Remote Start Installation Kit had been installed previously on the suspect vehicle. DIAGNOSIS: If the customer has experienced the above condition, and the vehicle has had a Mopar Remote Start Installation Kit installed, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Install the Remote Start Service Repair Kit. Refer to the detailed instructions included with the repair kit. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 08-018-07 Date: 070623 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > Page 5614 Remote Start System - RKE Inop/Alarm Sounds NUMBER: 08-018-07 GROUP: Electrical DATE: June 23, 2007 SUBJECT: Mopar Remote Start System - RKE - Intermittent Operation Or Alarm May Sound OVERVIEW: This bulletin involves the installation of a Mopar Remote Start System - Service Repair Kit. MODELS: 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) 2007 (HB/HG) Durango/Aspen 2007 (JK) Wrangler 2008 (J527) Sebring Convertible 2007 (JS) Sebring 2007-2008 (JS) Avenger 2007 (KA) Nitro 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to vehicles installed with a Mopar Remote Start Installation Kit. SYMPTOM/CONDITION: On vehicles that have had a Mopar Remote Start installation Kit installed by a dealer, the customer may experience one or more of the following conditions: A). ON ALL VEHICLES: An intermittent operation of the Remote Keyless Entry (RKE) system. At times, the RKE system may not function as designed. This may include intermittent operation of: lock/unlock mode, remote start mode, or panic mode. The vehicle may be operated manually without issue using the ignition key to open or lock the door, and to start the vehicle. B). ON RAM TRUCK AND DURANGO/ASPEN VEHICLES ONLY: The vehicle alarm may sound when the RKE system is activated by use of the key FOB. Deactivation of the vehicle alarm occurs when the vehicle engine is started using the ignition switch and key. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > Page 5615 The above condition(s) may be present ONLY if one of the following specific kit part numbers for the Mopar Remote Start Installation Kit had been installed previously on the suspect vehicle. DIAGNOSIS: If the customer has experienced the above condition, and the vehicle has had a Mopar Remote Start Installation Kit installed, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Install the Remote Start Service Repair Kit. Refer to the detailed instructions included with the repair kit. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 18-018-07 Date: 070623 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > Page 5616 Remote Starting System - RKE, Int. Operation/Alarm NUMBER: 18-018-07 GROUP: Electrical DATE: June 23, 2007 SUBJECT: Mopar Remote Start System - RKE - Intermittent Operation Or Alarm May Sound OVERVIEW: This bulletin involves the installation of a Mopar Remote Start System - Service Repair Kit. MODELS: 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) 2007 (HB/HG) Durango/Aspen 2007 (JK) Wrangler 2008 (J527) Sebring Convertible 2007 (JS) Sebring 2007-2008 (JS) Avenger 2007 (KA) Nitro 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to vehicles installed with a Mopar Remote Start Installation Kit. SYMPTOM/CONDITION: On vehicles that have had a Mopar Remote Start installation Kit installed by a dealer, the customer may experience one or more of the following conditions: A). ON ALL VEHICLES: An intermittent operation of the Remote Keyless Entry (RKE) system. At times, the RKE system may not function as designed. This may include intermittent operation of: lock/unlock mode, remote start mode, or panic mode. The vehicle may be operated manually without issue using the ignition key to open or lock the door, and to start the vehicle. B). ON RAM TRUCK AND DURANGO/ASPEN VEHICLES ONLY: The vehicle alarm may sound when the RKE system is activated by use of the key FOB. Deactivation of the vehicle alarm occurs when the vehicle engine is started using the ignition switch and key. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > Page 5617 The above condition(s) may be present ONLY if one of the following specific kit part numbers for the Mopar Remote Start Installation Kit had been installed previously on the suspect vehicle. DIAGNOSIS: If the customer has experienced the above condition, and the vehicle has had a Mopar Remote Start Installation Kit installed, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Install the Remote Start Service Repair Kit. Refer to the detailed instructions included with the repair kit. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 08-018-07 Date: 070623 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > Page 5618 Remote Start System - RKE Inop/Alarm Sounds NUMBER: 08-018-07 GROUP: Electrical DATE: June 23, 2007 SUBJECT: Mopar Remote Start System - RKE - Intermittent Operation Or Alarm May Sound OVERVIEW: This bulletin involves the installation of a Mopar Remote Start System - Service Repair Kit. MODELS: 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) 2007 (HB/HG) Durango/Aspen 2007 (JK) Wrangler 2008 (J527) Sebring Convertible 2007 (JS) Sebring 2007-2008 (JS) Avenger 2007 (KA) Nitro 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to vehicles installed with a Mopar Remote Start Installation Kit. SYMPTOM/CONDITION: On vehicles that have had a Mopar Remote Start installation Kit installed by a dealer, the customer may experience one or more of the following conditions: A). ON ALL VEHICLES: An intermittent operation of the Remote Keyless Entry (RKE) system. At times, the RKE system may not function as designed. This may include intermittent operation of: lock/unlock mode, remote start mode, or panic mode. The vehicle may be operated manually without issue using the ignition key to open or lock the door, and to start the vehicle. B). ON RAM TRUCK AND DURANGO/ASPEN VEHICLES ONLY: The vehicle alarm may sound when the RKE system is activated by use of the key FOB. Deactivation of the vehicle alarm occurs when the vehicle engine is started using the ignition switch and key. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > Page 5619 The above condition(s) may be present ONLY if one of the following specific kit part numbers for the Mopar Remote Start Installation Kit had been installed previously on the suspect vehicle. DIAGNOSIS: If the customer has experienced the above condition, and the vehicle has had a Mopar Remote Start Installation Kit installed, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Install the Remote Start Service Repair Kit. Refer to the detailed instructions included with the repair kit. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations Neutral Safety Switch: Locations Component ID: 340 Component : SWITCH-CLUTCH INTERLOCK Connector: Name : SWITCH-CLUTCH INTERLOCK Color : BLACK # of pins : 3 Qualifier : (MTX) Pin Description Circuit 1 CLUTCH UPSTOP SWITCH SIGNAL T26 20DG/OR 2 GROUND Z925 20BK/OR 2 GROUND Z961 20BK/YL 3 CLUTCH INTERLOCK SIGNAL T141 20YL/RD Component Location - 44 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Page 5623 Component Location - 47 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Page 5624 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Page 5625 Neutral Safety Switch: Diagrams Component ID: 340 Component : SWITCH-CLUTCH INTERLOCK Connector: Name : SWITCH-CLUTCH INTERLOCK Color : BLACK # of pins : 3 Qualifier : (MTX) Pin Description Circuit 1 CLUTCH UPSTOP SWITCH SIGNAL T26 20DG/OR 2 GROUND Z925 20BK/OR 2 GROUND Z961 20BK/YL 3 CLUTCH INTERLOCK SIGNAL T141 20YL/RD Component Location - 44 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Page 5626 Component Location - 47 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Page 5627 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations Starter Motor: Locations Component ID: 337 Component : STARTER Connector: Name : STARTER Color : BLACK # of pins : 1 Pin Description Circuit 1 STARTER CONTROL OUTPUT T750 16YL/GY Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 5631 Component Location - 15 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 5632 Component Location - 18 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 5633 Connector: Name : STARTER-EYELET-BATTERY SIDE Color : # of pins : 1 Pin Description Circuit 1 B(+) A0 4RD Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 5634 Component Location - 15 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 5635 Component Location - 18 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 5636 Connector: Name : STARTER-EYELET-GENERATOR SIDE Color : # of pins : 1 Pin Description Circuit 1 B(+) A802 8LB Pin Description Circuit 1 B(+) A802 10DG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 5637 Component Location - 14 Component Location - 15 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 5638 Component Location - 18 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 5639 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 5640 Starter Motor: Diagrams Component ID: 337 Component : STARTER Connector: Name : STARTER Color : BLACK # of pins : 1 Pin Description Circuit 1 STARTER CONTROL OUTPUT T750 16YL/GY Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 5641 Component Location - 15 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 5642 Component Location - 18 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 5643 Connector: Name : STARTER-EYELET-BATTERY SIDE Color : # of pins : 1 Pin Description Circuit 1 B(+) A0 4RD Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 5644 Component Location - 15 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 5645 Component Location - 18 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 5646 Connector: Name : STARTER-EYELET-GENERATOR SIDE Color : # of pins : 1 Pin Description Circuit 1 B(+) A802 8LB Pin Description Circuit 1 B(+) A802 10DG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 5647 Component Location - 14 Component Location - 15 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 5648 Component Location - 18 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 5649 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Removal Starter Motor: Service and Repair Removal 2.0/2.4L 1. Open hood. 2. Remove air cleaner box and air tube. 3. Disconnect and isolate the battery negative cable 4. Remove starter motor mounting bolt. 5. Disconnect the electrical connector at throttle body. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Removal > Page 5652 6. Remove Throttle body bolts and remove throttle body. 7. Push starter under intake manifold. 8. Tip starter nose toward cooling module. 9. Pull starter up and out. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Removal > Page 5653 10. Disconnect starter motor wiring. 11. Remove starter motor from vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Removal > Page 5654 Starter Motor: Service and Repair Installation 2.0/2.4L 1. Connect starter motor wiring. Tighten battery cable nut to 10 Nm (90 in. lbs.). 2. Reinstall starter motor into vehicle lower engine compartment. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Removal > Page 5655 3. Loose install starter into position. 4. Install throttle body 5. Install throttle body bracket. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Removal > Page 5656 6. Install starter motor mounting bolts and tighten to 54 Nm (40 ft. lbs.). 7. Connect throttle body electrical connector. 8. Install air cleaner box and inlet tube. 9. Lower vehicle. 10. Connect battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > Power Outlet-AC Auxiliary Power Outlet: Locations Power Outlet-AC Component ID: 175 Component : POWER OUTLET-AC Connector: Name : POWER OUTLET-AC Color : ORANGE # of pins : 6 Qualifier : (EXCEPT EXPORT) Pin Description Circuit 1 INVERTER ENABLE SWITCH SIGNAL P805 18LG/LB 2-3 110 VOLT AC LINE 1 P801 18LG 4 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F996 18PK/YL 5-6 110 VOLT AC COMMON P809 18LG/TN Component Location - 40 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > Power Outlet-AC > Page 5662 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > Power Outlet-AC > Page 5663 Auxiliary Power Outlet: Locations Power Outlet-Instrument Panel Component ID: 176 Component : POWER OUTLET-INSTRUMENT PANEL Connector: Name : POWER OUTLET-INSTRUMENT PANEL Color : GRAY # of pins : 3 Pin Description Circuit 1 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F986 20PK/BK 2-3 GROUND Z940 20BK/LG Component Location - 35 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > Power Outlet-AC > Page 5664 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: Provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5667 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5668 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5669 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5670 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5671 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5672 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5673 5. Release the Secondary Terminal Lock, if required (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5674 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5675 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5676 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5677 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5678 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5679 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5680 Auxiliary Power Outlet: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5681 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5682 STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5683 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5684 Auxiliary Power Outlet: Connector Views Power Outlet-AC Component ID: 175 Component : POWER OUTLET-AC Connector: Name : POWER OUTLET-AC Color : ORANGE # of pins : 6 Qualifier : (EXCEPT EXPORT) Pin Description Circuit 1 INVERTER ENABLE SWITCH SIGNAL P805 18LG/LB 2-3 110 VOLT AC LINE 1 P801 18LG 4 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F996 18PK/YL 5-- 6 110 VOLT AC COMMON P809 18LG/TN Component Location - 40 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5685 Power Outlet-Instrument Panel Component ID: 176 Component : POWER OUTLET-INSTRUMENT PANEL Connector: Name : POWER OUTLET-INSTRUMENT PANEL Color : GRAY # of pins : 3 Pin Description Circuit Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5686 1 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F986 20PK/BK 2-3 GROUND Z940 20BK/LG Component Location - 35 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5687 Auxiliary Power Outlet: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-41-02 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5688 8w-41-03 Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description and Operation > Description Auxiliary Power Outlet: Description and Operation Description DESCRIPTION INSTRUMENT PANEL MOUNTED An instrument panel mounted cigar lighter/power outlet receptacle is optional equipment on this model. On models equipped with the optional Smoker's Package, the cigar lighter knob and heating element are included. On models without the Smoker's Package, the cigar lighter receptacle is equipped with a snap fit plastic cap and is treated as an auxiliary power outlet. The cigar lighter receptacle is installed in the instrument panel accessory switch bezel, which is located near the bottom of the instrument panel center stack area, below the radio. The cigar lighter base is secured by a snap fit within the center lower bezel. This power outlet has a constant 12 volt battery feed. The cigar lighter receptacle is serviced with the accessory switch bezel and if defective, the entire switch bezel must be replaced. The plastic cap and the knob and heating element unit are available for service replacement. These components cannot be repaired and, if faulty or damaged, they must be replaced. FRONT CONSOLE AND REAR CARGO MOUNTED A front console mounted power outlet is standard equipment and a rear cargo area power outlet is optional equipment on this model. The front console mounted power outlet is mounted near the front of the console just in front of the cup holders. This outlet can be used as a cigar lighter or power outlet, but only has 12 volt battery voltage when the ignition is in the ON or ACC positions. The rear power outlet is installed in the right rear quarter trim panel, near the spare tire jack (2). The power outlet base and mount are secured by a snap fit within the quarter trim panel. A plastic protective cap snaps into the power outlet base when the power outlet is not being used, and hangs from the power outlet base mount by an integral bail strap while the power outlet is in use. While the power outlet is very similar to a cigar lighter base unit, it does not include the two small spring-clip retainers inside the bottom of the receptacle shell that are used to secure the cigar lighter heating element to the insulated contact. It has 12 volt battery voltage when the ignition is in the ON or ACC positions. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description and Operation > Description > Page 5691 Auxiliary Power Outlet: Description and Operation Operation OPERATION CIGAR LIGHTER/POWER OUTLET The cigar lighter consists of two major components: a knob and heating element unit, and the cigar lighter base or receptacle shell. The receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The cigar lighter knob and heating element are encased within a spring-loaded housing, which also features a sliding protective heat shield. When the knob and heating element are inserted in the receptacle shell, the heating element resistor coil is grounded through its housing to the receptacle shell. If the cigar lighter knob is pushed inward, the heat shield slides up toward the knob exposing the heating element, and the heating element extends from the housing toward the insulated contact in the bottom of the receptacle shell. Two small spring-clip retainers are located on either side of the insulated contact inside the bottom of the receptacle shell. These clips engage and hold the heating element against the insulated contact long enough for the resistor coil to heat up. When the heating element is engaged with the contact, battery current can flow through the resistor coil to ground, causing the resistor coil to heat. When the resistor coil becomes sufficiently heated, excess heat radiates from the heating element causing the spring-clips to expand. Once the spring-clips expand far enough to release the heating element, the spring-loaded housing forces the knob and heating element to pop back outward to their relaxed position. When the cigar lighter knob and element are pulled out of the receptacle shell, the protective heat shield slides downward on the housing so that the heating element is recessed and shielded around its circumference for safety. POWER OUTLET The power outlet base or receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The power outlet receives battery voltage from a fuse in the Totally Integrated Power Module (TIPM) through a fuse in the fuse block when the ignition is in the ON or ACC positions. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Cigar Lighter/Power Outlet Auxiliary Power Outlet: Service and Repair Cigar Lighter/Power Outlet Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Look inside and note position of the retaining bosses (1). 3. Using special tool 9857 Power Outlet Remover. Insert the tool forcing the bosses out of base. 4. Pull out the base through mounting ring by gently rocking the tool (3). 5. Disconnect the base wires. 6. Set base aside and remove base mount ring. Installation INSTALLATION 1. Position mount ring to the instrument panel and feed the wires through ring. Index the cap and the mount ring with the index tab at 9 o'clock to the key in the instrument panel. Install the ring. 2. Connect wires to base. Orient base alignment rib at 11 o'clock to mate the groove in mount ring at the same location. 3. Push base into the bezel till it locks. 4. Install cigar lighter cap. 5. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Cigar Lighter/Power Outlet > Page 5694 Auxiliary Power Outlet: Service and Repair Power Outlet-AC Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the center console. 3. Disconnect electrical connector. 4. Remove AC power outlet. Installation INSTALLATION 1. Install the AC power outlet. 2. Connect electrical connector. 3. Install the center console. 4. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Description and Operation > Description Electrical Accessory Panel: Description and Operation Description DESCRIPTION All of the electrical current distributed throughout this vehicle is directed through the standard equipment Totally Integrated Power Module (TIPM) (1). The molded plastic TIPM housing is located in the left front corner of the engine compartment, just behind the air cleaner housing and the battery. The TIPM housing has a molded plastic cover. The TIPM cover is easily removed for service access and has a convenient fuse and relay layout label affixed to the inside surface of the cover to ensure proper component identification. The TIPM housing is secured to the left inner fender well an indexing pin and one screw. All of the TIPM outputs are through the integral engine compartment wire harness. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Description and Operation > Description > Page 5699 Electrical Accessory Panel: Description and Operation Operation OPERATION All of the current from the generator cable connection goes to the battery through a 10 gauge fusible link that is secured with a nut to the positive battery terminal at the starter. Internal connection of all the Totally Integrated Power Module (TIPM) circuits is accomplished by an intricate network of hard wiring and bus bars. Refer to Wiring Diagrams for complete circuit diagrams. The fusible link, fuses and relays are available for service replacement. The TIPM unit cannot be repaired and is only serviced as a unit with the engine compartment wire harness. If the TIPM is inoperative or damaged, the engine compartment wire harness assembly must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Service and Repair > Removal Electrical Accessory Panel: Service and Repair Removal REMOVAL The TIPM (TIPM) is serviced as a unit with the engine compartment wire harness. If any internal circuit of the TIPM or the TIPM housing is faulty or damaged, the entire TIPM and engine compartment wire harness unit must be replaced. Refer to Wiring Diagrams for the locations of the affected connectors. 1. Open hood. 2. Disconnect and isolate the battery negative cable. 3. Disconnect each of the engine compartment wire harness connectors. 4. Remove the fasteners that secure each of the engine compartment wire harness ground eyelets to the vehicle body and chassis components. 5. Disengage each of the retainers that secure the engine compartment wire harness to the vehicle body and chassis components. 6. Disengage and remove the TIPM housing from its mounting bracket. 7. Remove the TIPM and the engine compartment wire harness from the engine compartment as a unit. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Service and Repair > Removal > Page 5702 Electrical Accessory Panel: Service and Repair Installation INSTALLATION The Totally Integrated Power Module (TIPM) is serviced as a unit with the engine compartment wire harness. If any internal circuit of the TIPM or the TIPM housing is faulty or damaged, the entire TIPM and engine compartment wire harness unit must be replaced. NOTE: If the Totally Integrated Power Module (TIPM) is being replaced with a new unit, be certain to transfer each of the fuses and relays from the old TIPM to the proper cavities of the new TIPM. Refer to Wiring Diagrams for the proper TIPM cavity assignments. 1. Position the TIPM in the engine compartment. 2. Align the TIPM on its mounting bracket and install. 3. Route the engine compartment wire harness from the TIPM through the engine compartment, engaging each of the harness retainers to the mounting provisions in the vehicle body and chassis components. Refer to Wiring Diagrams for the harness routing and retainer locations. 4. Install and tighten the fasteners that secure each of the engine compartment wire harness ground eyelets to the vehicle body and chassis components. Refer to Wiring Diagrams for the ground eyelet locations. 5. Reconnect each of the engine compartment wire harness connectors. Refer to Wiring Diagrams for the locations of the affected connectors. 6. Torque nut retaining positive battery cable at TIPM to 96 - 141 Nm (85 - 130 in. lbs.). 7. Reconnect the battery negative cable. 8. Close hood. 9. Verify vehicle and system operation. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Customer Interest for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems - Intermittent Component Operation Fuse: Customer Interest Electrical Systems - Intermittent Component Operation NUMBER:08-016-06 REV. A GROUP: Electrical DATE: July 18, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-016-06, DATED MARCH 22, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF A VEHICLE BODY STYLE. SUBJECT: Intermittent Operation Of Electrical Components Due To Ignition Off Draw (IOD) Fuse Not Being Fully Seated MODELS: 2007 (PM) Caliber **2007 (MK-49) Compass** 2006 - 2007 (DHIDRID1) Ram Truck 2006 - 2007 (PT) Chrysler PT Cruiser DISCUSSION: The Ignition Off Draw (IOD) fuse is used to prevent battery discharge during shipping and long term storage of the vehicles. The IOD fuse is located in the Total Integrated Power Module (TI PM). If the fuse is not completely inserted partial contact of the fuse terminals could occur. When the vehicle is prepped for customer delivery, ensure that the fuse is fully engaged (Fig. 1). The IOD fuse must also be fully released to prevent battery drain from occurring when the vehicle is stored. When the IOD fuse holder is depressed into the carrier, an initial distinct detent will be felt to overcome the "pre-hold position". You must then continue to push straight down on the IOD pre-holder until no further downward movement is encountered. NOTE: If the fuse is not pushed down symmetrically, two detents MAY be felt as each side snaps past the pre-hold position. Push down until no further downward movement is encountered. On 2006 and 2007 PT and PM vehicles the circuits fed by the IOD fuse are: Radio, Security module & siren (BUX), Wireless Control Module (RKE & SKREEM), Hands Free Module, Satellite Radio, Power Mirrors, Clock, Memory Seat, Amplifier, CCN wake-up with ignition off and Homelink. On 2006 and 2007 DR, DH or D1 vehicles the circuits fed by the IOD fuse are: Radio, EVIC, Wireless Control Module (RKE & SKREEM), Hands Free Module, Satellite Radio, Video Screen, CCN wake-up with ignition off, Underhood Lamp, CCN Interior Lighting Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Customer Interest for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems - Intermittent Component Operation > Page 5711 POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems Intermittent Component Operation Fuse: All Technical Service Bulletins Electrical Systems - Intermittent Component Operation NUMBER:08-016-06 REV. A GROUP: Electrical DATE: July 18, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-016-06, DATED MARCH 22, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF A VEHICLE BODY STYLE. SUBJECT: Intermittent Operation Of Electrical Components Due To Ignition Off Draw (IOD) Fuse Not Being Fully Seated MODELS: 2007 (PM) Caliber **2007 (MK-49) Compass** 2006 - 2007 (DHIDRID1) Ram Truck 2006 - 2007 (PT) Chrysler PT Cruiser DISCUSSION: The Ignition Off Draw (IOD) fuse is used to prevent battery discharge during shipping and long term storage of the vehicles. The IOD fuse is located in the Total Integrated Power Module (TI PM). If the fuse is not completely inserted partial contact of the fuse terminals could occur. When the vehicle is prepped for customer delivery, ensure that the fuse is fully engaged (Fig. 1). The IOD fuse must also be fully released to prevent battery drain from occurring when the vehicle is stored. When the IOD fuse holder is depressed into the carrier, an initial distinct detent will be felt to overcome the "pre-hold position". You must then continue to push straight down on the IOD pre-holder until no further downward movement is encountered. NOTE: If the fuse is not pushed down symmetrically, two detents MAY be felt as each side snaps past the pre-hold position. Push down until no further downward movement is encountered. On 2006 and 2007 PT and PM vehicles the circuits fed by the IOD fuse are: Radio, Security module & siren (BUX), Wireless Control Module (RKE & SKREEM), Hands Free Module, Satellite Radio, Power Mirrors, Clock, Memory Seat, Amplifier, CCN wake-up with ignition off and Homelink. On 2006 and 2007 DR, DH or D1 vehicles the circuits fed by the IOD fuse are: Radio, EVIC, Wireless Control Module (RKE & SKREEM), Hands Free Module, Satellite Radio, Video Screen, CCN wake-up with ignition off, Underhood Lamp, CCN Interior Lighting Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems Intermittent Component Operation > Page 5717 POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Page 5718 Fuse: Locations Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Page 5719 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Page 5720 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Page 5721 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Page 5722 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: Provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5725 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5726 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5727 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5728 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5729 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5730 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5731 5. Release the Secondary Terminal Lock, if required (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5732 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5733 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5734 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5735 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5736 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5737 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5738 Fuse: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5739 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5740 STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5741 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Page 5742 Fuse: Application and ID Totally Integrated Power Module Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Page 5743 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations Fuse Block: Locations Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Page 5747 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Page 5748 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Page 5749 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Page 5750 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: Provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5753 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5754 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5755 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5756 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5757 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5758 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5759 5. Release the Secondary Terminal Lock, if required (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5760 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5761 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5762 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5763 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5764 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5765 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5766 Fuse Block: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5767 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5768 STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5769 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 5770 Fuse Block: Application and ID Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 5771 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 5772 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 5773 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 5774 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Description and Operation > Description Fuse Block: Description and Operation Description DESCRIPTION An electrical Fuse Block is located in the left front bumper fascia. It serves to simplify and centralize numerous electrical components, as well as to distribute electrical current to many of the accessory systems in the vehicle. There are two clips that retain the fuse block cover to the fuse block. The cover can be removed to service the fuses and relays by depressing the clips and lifting off the cover. If fuse block wire terminal or insulator service is required the complete fuse block assembly must be removed. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Description and Operation > Description > Page 5777 Fuse Block: Description and Operation Operation OPERATION The fuse block houses relays and blade-type fuses. The fuses, relays and fuse block unit are available for service replacement. Refer to Wiring Diagrams for complete circuit diagrams. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Removal Fuse Block: Service and Repair Removal REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the front bumper fascia. 3. Depress mounting clips and lift the fuse block off the bracket. 4. Remove the wire harness and fuse block. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Removal > Page 5780 Fuse Block: Service and Repair Installation INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Install the new wire harness and fuse block into the vehicle. 2. Position the fuse block onto the mounting bracket and push down until the mounting clips are fully seated. 3. Install the front bumper fascia. 4. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Mini ISO Relay > Component Information > Service and Repair > Removal Mini ISO Relay: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove cover from Totally Integrated Power module (TIPM). 3. Using special tool C-4817 (1), grip the relay (2) by the sides and pull upward with an even effort. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Mini ISO Relay > Component Information > Service and Repair > Removal > Page 5785 Mini ISO Relay: Service and Repair Installation INSTALLATION 1. Align relay (2) with Totally Integrated Power Module (TIPM) and press into position. 2. Install cover to TIPM. 3. Connect battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Recalls: > G42 > Jan > 08 > Campaign - TIPM Software Update for Antitheft System Technical Service Bulletin # G42 Date: 080101 Campaign - TIPM Software Update for Antitheft System January 2008 Distributor/Dealer Service Instructions for: Customer Satisfaction Notice G42 TIPM Re-Configure, Anti-Theft System Models 2007 2008 (JS/PM/MK) Sebring, Avenger, Caliber, Compass and Patriot vehicles (International Markets Only) NOTE: This customer satisfaction notice applies only to the above vehicles built at the Sterling Heights Assembly Plant through July 25, 2007 (MDH 0725XX) and the Belvidere Assembly Plant through July 23, 2007 (MDH 0723XX). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this customer satisfaction notice. IMPORTANT: Some of the involved vehicles may be in distributor/dealer used vehicle inventory. Distributors/Dealers should complete this recall service on these vehicles before retail delivery. Distributors/Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Totally Integrated Power Module (TIPM) vehicles may be configured incorrectly preventing the Anti-Theft Security System from operating properly. Repair The Totally Integrated Power Module (TIPM) must be Re-Configured. Special Tools These existing special tools are required to perform this repair. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Recalls: > G42 > Jan > 08 > Campaign - TIPM Software Update for Antitheft System > Page 5794 Use the labor operation number and time allowance shown. Distributor/ Dealer Notification and Vehicle List Regional offices will receive an electronic list of involved vehicles. The Vehicle List is arranged by Distributor/Dealer code and in Vehicle Identification Number (VIN) sequence. The lists are for Distributor/Dealer reference in arranging for service of involved vehicles. Owner Notification and Service Scheduling All involved vehicle owners should be notified of the service requirement by their Distributor/Dealer. Owners are requested to schedule appointments for this service. A sample copy of the owner notification letter is included. Vehicle Lists, Global Recall System, VIP and Distributor/Dealer Follow up All involved vehicles have been entered into the Global Recall System (GRS) and Vehicle Information Plus (VIP) for Distributor/Dealer inquiry as needed. GRS provides involved Distributors/Dealers with an updated VIN list of their incomplete vehicles. Completed vehicles are removed from GRS within several days of repair claim submission. Distributors/Dealers must perform this repair on all unsold vehicles before retail delivery. Distributors/Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Additional Information If you have any questions or need assistance in completing this action, please contact your International Service and Parts Manager. Global Service & Parts - International Chrysler LLC Service Procedure NOTE: Use StarSCAN(R) to perform this Customer Satisfaction Notice. This procedure must be performed using software release 8.02 or higher. Re-Configure the TIPM using StarSCAN(R) 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN(R) Ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN® vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN(R). 5. Re-Configure the TIPM as Follows: a. With the StarSCAN(R) on the "Home" screen, select "ECU View". b. Select "TIPMCGW Central Gateway" in the list of modules. c. Select "Misc Functions". Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Recalls: > G42 > Jan > 08 > Campaign - TIPM Software Update for Antitheft System > Page 5795 d. Select "Restore Vehicle Configuration". e. Press "Start". f. Follow the prompts listed on the StarSCAN(R). g. When prompted, Enter the full 17 digit VIN found on the VIN plate. NOTE: Assure the correct VIN is input into the StarSCAN(R). h. Select "Next". NOTE: The StarSCAN(R) must be connected to the dealer network drop. i. Follow the prompts listed on the StarSCAN(R). 6. Check and clear any Diagnostic Trouble Codes (DTC's) that may have been set. 7. Turn the ignition key to the "OFF" position and remove the StarSCAN(R) unit, StarSCAN(R) cable, and battery charger from the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-007-08A > Jul > 08 > Antitheft System Engine No Crank/No Start Condition Power Distribution Module: Customer Interest Antitheft System - Engine No Crank/No Start Condition NUMBER: 08-007-08 REV. A GROUP: Electrical DATE: July 04,2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-007-08, DATED MARCH 04, 2008. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. DO NOT ORDER PART NUMBER 05026070AP UNTIL JULY 21, 2008. ALL OTHER PART NUMBERS ARE AVAILABLE NOW. SUBJECT: No Engine Crank Or No Engine Start Due To Electronic Lockup Of The WCM / SKREEM OVERVIEW: This bulletin involves the replacement of the Wireless Control Module (WCM), and if equipped, the replacement of the Electric Steering Column Lock (ELV). The WCM is also referred to as the Sentry Key Remote Entry Module (SKREEM). MODELS: 2007 - 2008 (DR/DH/D1/DC/DM) Ram Truck (1500/2500/3500/4500/5500) 2007 - 2008 (JK) Wrangler 2007 - 2008 (J1) Sebring (China) 2007 - 2008 (JS) Avenger/Sebring 2007 - 2008 (KA) Nitro 2008 (KK) Liberty/Cherokee 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber 2006 - 2008 (PT) Chrysler PT Cruiser NOTE: This bulletin applies to vehicles built on or before May 05, 2008 (MDH 0505XX). SYMPTOM/CONDITION: The customer will experience a no engine crank AND a no engine start condition. Also, the remote keyless entry (RKE) system will not operate. This condition may be due to an electrostatic discharge (ESD) from the ignition key into the Wireless Control Module (WCM), causing the WCM to electronically lockup. This condition may occur more frequently in dry and/or cold weather conditions where a sufficient electrostatic charge is more easily produced. This condition is corrected by the replacement of the WCM. DIAGNOSIS: 1. With the condition present (i.e. the vehicle in the no crank / no start condition), connect the StarSCAN(R) scan tool to the vehicle. 2. Turn the ignition switch to the "ON position, and power up the StarSCAN(R). 3. If the WCM is electronically locked up, the StarSCAN(R) will display the WCM as being "off bus". 4. If the no crank / no start condition is present, and the WCM is "off bus", then reset the WCM by temporarily removing the IOD fuse (with the key out of the ignition switch), wait for 10 seconds and then reinstall the IOD fuse. 5. With the IOD fuse reset having been performed, verify that the vehicle will now crank, start, and run. 6. If the condition is temporarily corrected by performing the above steps, and if the part number of the WCM is earlier than the part number of the WCM listed in the part reference table in the Service Bulletin Parts Required Section below, then perform the Repair Procedure. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-007-08A > Jul > 08 > Antitheft System Engine No Crank/No Start Condition > Page 5801 PARTS REQUIRED: NOTE: The part numbers listed in the following part reference table are to be used as A GUIDE to help determine if the WCM, that is currently in the vehicle, may require replacement. If it is determined that the WCM requires replacement, then ALWAYS REFER TO THE PARTS MANUAL to determine the correct WCM for the specific vehicle in question. In some earlier model years, the WCM may rule (supersede) to one of the part numbers listed in the table. ALWAYS REFER TO THE PARTS MANUAL (not the part reference table) to determine the correct part number ruling (supercedence / substitution). MAKE CERTAIN THAT THE CORRECT WCM IS ORDERED THE FIRST TIME FOR THE SPECIFIC VEHICLE IN QUESTION. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-007-08A > Jul > 08 > Antitheft System Engine No Crank/No Start Condition > Page 5802 REPAIR PROCEDURE: NOTE: If the vehicle (a JS model vehicle in certain International markets) is equipped with an Electric Steering Column Lock (ELV), then the WCM and the ELV must be replaced. Replace the WCM and then the ELV. Next program the WCM and at least one (1) ignition key BEFORE programming the ELV. IMPORTANT: Not following this repair process correctly will cause the new ELV to fail. NOTE: Insert the ignition key into the ignition lock cylinder. This will move the shaft lock module locking bolt to the unlocked position. LEAVE the key in the lock cylinder while the shaft lock module is being removed. 1. If vehicle is equipped with a Steering Shaft Lock Module (JS - Avenger I Stratus - some International Markets), then the Shaft Lock Module will require replacement. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Security Information > Module, Shaft Lock > Removal and Installation. NOTE: The shaft lock module cannot be removed from the steering column while the locking bolt is in the locked position without irreversibly damaging the column. Before attempting service, the ignition key must have been inserted into the ignition lock cylinder. Then rotate the steering wheel from side to side. If the steering wheel can be rotated, the locking bolt is in the unlocked position. Leave the key in the ignition lock cylinder until shaft lock module removal has been completed. If the steering wheel cannot be rotated, test and repair the wiring circuits between the module and the ignition switch as required. If no problem is found in these circuits, the module has failed with the locking bolt in the locked position and both the module and the steering column must be replaced with new units. 2. Replace the WCM/SKREEM. Refer to TechCONNECT for detailed service information. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Service Information > Module, Sentry Key Remote Entry > Removal and Installation. NOTE: Obtain the vehicle PIN number prior to programming WCM/SKREEM or ELV. NOTE: If during the following steps the PIN number is properly entered but is rejected, then reenter the PIN number again until it is accepted. 3. After both the WCM/SKREEM and the ELV (if equipped) have been replaced, Program the WCM/SKREEM as follows: a. Turn the ignition key to the ON position, (Engine Off) b. Connect the scan tool (StarSCAN(R)) to the data link connector and turn the ignition to the RUN position, (engine off). c. Select "ECU View." d. Scroll down and select "WCM" in the list of modules. e. Select "Misc. Functions." f. Scroll to "WCM Replaced." g. Press "Start". h. Press "Next". i. Select "Show Keyboard". j. Enter the vehicle PIN number. k. Select "Next". l. Verify PIN is correct. m. Select "Next". n. Follow on-screen prompts to complete WCM function programing for Tire Pressure Monitoring (TPM) and so on. 0. Turn the ignition key to the OFF position. Wait 30 seconds. p. Turn the ignition key to the ON position, (Engine Off) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-007-08A > Jul > 08 > Antitheft System Engine No Crank/No Start Condition > Page 5803 q. Select "ECU View". r. Scroll down and select "WCM" in the list of modules. s. Select "Misc. Functions." t. Select "Program Ign. Keys" and follow on-screen prompts. u. Select "Complete". v. Verify ignition key will start vehicle and the Remote Keyless Entry (RKE) functions operate. CAUTION: If the vehicle is equipped with a Shaft Lock Module (used in some International Markets on JS model vehicles), then at least one (1 ignition key must have been programmed to the new WCM BEFORE the new Shaft Lock Module is "married" to the new WCM. 4. Is the vehicle equipped with Steering Shaft Lock Module (ELV)? a. Yes >> Proceed to Step # 5. b. No >>Repair is complete. 5. Program the ELV as follows; a. Select "ECU View". b. Scroll down and select "WCM" in the list of modules. c. Select "Misc. Functions". d. Scroll to "ELV Replaced." e. Press "Start". f. When complete, verify steering shaft lock mechanism is operating. Remove and insert key from the ignition lock cylinder and listen for solenoid "click at lower end of column. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-007-08A > Jul > 08 > Antitheft System Engine No Crank/No Start Condition > Page 5804 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition Power Distribution Module: All Technical Service Bulletins Antitheft System - Engine No Crank/No Start Condition NUMBER: 08-007-08 REV. A GROUP: Electrical DATE: July 04,2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-007-08, DATED MARCH 04, 2008. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. DO NOT ORDER PART NUMBER 05026070AP UNTIL JULY 21, 2008. ALL OTHER PART NUMBERS ARE AVAILABLE NOW. SUBJECT: No Engine Crank Or No Engine Start Due To Electronic Lockup Of The WCM / SKREEM OVERVIEW: This bulletin involves the replacement of the Wireless Control Module (WCM), and if equipped, the replacement of the Electric Steering Column Lock (ELV). The WCM is also referred to as the Sentry Key Remote Entry Module (SKREEM). MODELS: 2007 - 2008 (DR/DH/D1/DC/DM) Ram Truck (1500/2500/3500/4500/5500) 2007 - 2008 (JK) Wrangler 2007 - 2008 (J1) Sebring (China) 2007 - 2008 (JS) Avenger/Sebring 2007 - 2008 (KA) Nitro 2008 (KK) Liberty/Cherokee 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber 2006 - 2008 (PT) Chrysler PT Cruiser NOTE: This bulletin applies to vehicles built on or before May 05, 2008 (MDH 0505XX). SYMPTOM/CONDITION: The customer will experience a no engine crank AND a no engine start condition. Also, the remote keyless entry (RKE) system will not operate. This condition may be due to an electrostatic discharge (ESD) from the ignition key into the Wireless Control Module (WCM), causing the WCM to electronically lockup. This condition may occur more frequently in dry and/or cold weather conditions where a sufficient electrostatic charge is more easily produced. This condition is corrected by the replacement of the WCM. DIAGNOSIS: 1. With the condition present (i.e. the vehicle in the no crank / no start condition), connect the StarSCAN(R) scan tool to the vehicle. 2. Turn the ignition switch to the "ON position, and power up the StarSCAN(R). 3. If the WCM is electronically locked up, the StarSCAN(R) will display the WCM as being "off bus". 4. If the no crank / no start condition is present, and the WCM is "off bus", then reset the WCM by temporarily removing the IOD fuse (with the key out of the ignition switch), wait for 10 seconds and then reinstall the IOD fuse. 5. With the IOD fuse reset having been performed, verify that the vehicle will now crank, start, and run. 6. If the condition is temporarily corrected by performing the above steps, and if the part number of the WCM is earlier than the part number of the WCM listed in the part reference table in the Service Bulletin Parts Required Section below, then perform the Repair Procedure. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 5810 PARTS REQUIRED: NOTE: The part numbers listed in the following part reference table are to be used as A GUIDE to help determine if the WCM, that is currently in the vehicle, may require replacement. If it is determined that the WCM requires replacement, then ALWAYS REFER TO THE PARTS MANUAL to determine the correct WCM for the specific vehicle in question. In some earlier model years, the WCM may rule (supersede) to one of the part numbers listed in the table. ALWAYS REFER TO THE PARTS MANUAL (not the part reference table) to determine the correct part number ruling (supercedence / substitution). MAKE CERTAIN THAT THE CORRECT WCM IS ORDERED THE FIRST TIME FOR THE SPECIFIC VEHICLE IN QUESTION. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 5811 REPAIR PROCEDURE: NOTE: If the vehicle (a JS model vehicle in certain International markets) is equipped with an Electric Steering Column Lock (ELV), then the WCM and the ELV must be replaced. Replace the WCM and then the ELV. Next program the WCM and at least one (1) ignition key BEFORE programming the ELV. IMPORTANT: Not following this repair process correctly will cause the new ELV to fail. NOTE: Insert the ignition key into the ignition lock cylinder. This will move the shaft lock module locking bolt to the unlocked position. LEAVE the key in the lock cylinder while the shaft lock module is being removed. 1. If vehicle is equipped with a Steering Shaft Lock Module (JS - Avenger I Stratus - some International Markets), then the Shaft Lock Module will require replacement. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Security Information > Module, Shaft Lock > Removal and Installation. NOTE: The shaft lock module cannot be removed from the steering column while the locking bolt is in the locked position without irreversibly damaging the column. Before attempting service, the ignition key must have been inserted into the ignition lock cylinder. Then rotate the steering wheel from side to side. If the steering wheel can be rotated, the locking bolt is in the unlocked position. Leave the key in the ignition lock cylinder until shaft lock module removal has been completed. If the steering wheel cannot be rotated, test and repair the wiring circuits between the module and the ignition switch as required. If no problem is found in these circuits, the module has failed with the locking bolt in the locked position and both the module and the steering column must be replaced with new units. 2. Replace the WCM/SKREEM. Refer to TechCONNECT for detailed service information. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Service Information > Module, Sentry Key Remote Entry > Removal and Installation. NOTE: Obtain the vehicle PIN number prior to programming WCM/SKREEM or ELV. NOTE: If during the following steps the PIN number is properly entered but is rejected, then reenter the PIN number again until it is accepted. 3. After both the WCM/SKREEM and the ELV (if equipped) have been replaced, Program the WCM/SKREEM as follows: a. Turn the ignition key to the ON position, (Engine Off) b. Connect the scan tool (StarSCAN(R)) to the data link connector and turn the ignition to the RUN position, (engine off). c. Select "ECU View." d. Scroll down and select "WCM" in the list of modules. e. Select "Misc. Functions." f. Scroll to "WCM Replaced." g. Press "Start". h. Press "Next". i. Select "Show Keyboard". j. Enter the vehicle PIN number. k. Select "Next". l. Verify PIN is correct. m. Select "Next". n. Follow on-screen prompts to complete WCM function programing for Tire Pressure Monitoring (TPM) and so on. 0. Turn the ignition key to the OFF position. Wait 30 seconds. p. Turn the ignition key to the ON position, (Engine Off) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 5812 q. Select "ECU View". r. Scroll down and select "WCM" in the list of modules. s. Select "Misc. Functions." t. Select "Program Ign. Keys" and follow on-screen prompts. u. Select "Complete". v. Verify ignition key will start vehicle and the Remote Keyless Entry (RKE) functions operate. CAUTION: If the vehicle is equipped with a Shaft Lock Module (used in some International Markets on JS model vehicles), then at least one (1 ignition key must have been programmed to the new WCM BEFORE the new Shaft Lock Module is "married" to the new WCM. 4. Is the vehicle equipped with Steering Shaft Lock Module (ELV)? a. Yes >> Proceed to Step # 5. b. No >>Repair is complete. 5. Program the ELV as follows; a. Select "ECU View". b. Scroll down and select "WCM" in the list of modules. c. Select "Misc. Functions". d. Scroll to "ELV Replaced." e. Press "Start". f. When complete, verify steering shaft lock mechanism is operating. Remove and insert key from the ignition lock cylinder and listen for solenoid "click at lower end of column. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 5813 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > G42 > Jan > 08 > Campaign - TIPM Software Update for Antitheft System Technical Service Bulletin # G42 Date: 080101 Campaign - TIPM Software Update for Antitheft System January 2008 Distributor/Dealer Service Instructions for: Customer Satisfaction Notice G42 TIPM Re-Configure, Anti-Theft System Models 2007 2008 (JS/PM/MK) Sebring, Avenger, Caliber, Compass and Patriot vehicles (International Markets Only) NOTE: This customer satisfaction notice applies only to the above vehicles built at the Sterling Heights Assembly Plant through July 25, 2007 (MDH 0725XX) and the Belvidere Assembly Plant through July 23, 2007 (MDH 0723XX). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this customer satisfaction notice. IMPORTANT: Some of the involved vehicles may be in distributor/dealer used vehicle inventory. Distributors/Dealers should complete this recall service on these vehicles before retail delivery. Distributors/Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Totally Integrated Power Module (TIPM) vehicles may be configured incorrectly preventing the Anti-Theft Security System from operating properly. Repair The Totally Integrated Power Module (TIPM) must be Re-Configured. Special Tools These existing special tools are required to perform this repair. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > G42 > Jan > 08 > Campaign - TIPM Software Update for Antitheft System > Page 5818 Use the labor operation number and time allowance shown. Distributor/ Dealer Notification and Vehicle List Regional offices will receive an electronic list of involved vehicles. The Vehicle List is arranged by Distributor/Dealer code and in Vehicle Identification Number (VIN) sequence. The lists are for Distributor/Dealer reference in arranging for service of involved vehicles. Owner Notification and Service Scheduling All involved vehicle owners should be notified of the service requirement by their Distributor/Dealer. Owners are requested to schedule appointments for this service. A sample copy of the owner notification letter is included. Vehicle Lists, Global Recall System, VIP and Distributor/Dealer Follow up All involved vehicles have been entered into the Global Recall System (GRS) and Vehicle Information Plus (VIP) for Distributor/Dealer inquiry as needed. GRS provides involved Distributors/Dealers with an updated VIN list of their incomplete vehicles. Completed vehicles are removed from GRS within several days of repair claim submission. Distributors/Dealers must perform this repair on all unsold vehicles before retail delivery. Distributors/Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Additional Information If you have any questions or need assistance in completing this action, please contact your International Service and Parts Manager. Global Service & Parts - International Chrysler LLC Service Procedure NOTE: Use StarSCAN(R) to perform this Customer Satisfaction Notice. This procedure must be performed using software release 8.02 or higher. Re-Configure the TIPM using StarSCAN(R) 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN(R) Ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN® vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN(R). 5. Re-Configure the TIPM as Follows: a. With the StarSCAN(R) on the "Home" screen, select "ECU View". b. Select "TIPMCGW Central Gateway" in the list of modules. c. Select "Misc Functions". Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > G42 > Jan > 08 > Campaign - TIPM Software Update for Antitheft System > Page 5819 d. Select "Restore Vehicle Configuration". e. Press "Start". f. Follow the prompts listed on the StarSCAN(R). g. When prompted, Enter the full 17 digit VIN found on the VIN plate. NOTE: Assure the correct VIN is input into the StarSCAN(R). h. Select "Next". NOTE: The StarSCAN(R) must be connected to the dealer network drop. i. Follow the prompts listed on the StarSCAN(R). 6. Check and clear any Diagnostic Trouble Codes (DTC's) that may have been set. 7. Turn the ignition key to the "OFF" position and remove the StarSCAN(R) unit, StarSCAN(R) cable, and battery charger from the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition Power Distribution Module: All Technical Service Bulletins Antitheft System - Engine No Crank/No Start Condition NUMBER: 08-007-08 REV. A GROUP: Electrical DATE: July 04,2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-007-08, DATED MARCH 04, 2008. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. DO NOT ORDER PART NUMBER 05026070AP UNTIL JULY 21, 2008. ALL OTHER PART NUMBERS ARE AVAILABLE NOW. SUBJECT: No Engine Crank Or No Engine Start Due To Electronic Lockup Of The WCM / SKREEM OVERVIEW: This bulletin involves the replacement of the Wireless Control Module (WCM), and if equipped, the replacement of the Electric Steering Column Lock (ELV). The WCM is also referred to as the Sentry Key Remote Entry Module (SKREEM). MODELS: 2007 - 2008 (DR/DH/D1/DC/DM) Ram Truck (1500/2500/3500/4500/5500) 2007 - 2008 (JK) Wrangler 2007 - 2008 (J1) Sebring (China) 2007 - 2008 (JS) Avenger/Sebring 2007 - 2008 (KA) Nitro 2008 (KK) Liberty/Cherokee 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber 2006 - 2008 (PT) Chrysler PT Cruiser NOTE: This bulletin applies to vehicles built on or before May 05, 2008 (MDH 0505XX). SYMPTOM/CONDITION: The customer will experience a no engine crank AND a no engine start condition. Also, the remote keyless entry (RKE) system will not operate. This condition may be due to an electrostatic discharge (ESD) from the ignition key into the Wireless Control Module (WCM), causing the WCM to electronically lockup. This condition may occur more frequently in dry and/or cold weather conditions where a sufficient electrostatic charge is more easily produced. This condition is corrected by the replacement of the WCM. DIAGNOSIS: 1. With the condition present (i.e. the vehicle in the no crank / no start condition), connect the StarSCAN(R) scan tool to the vehicle. 2. Turn the ignition switch to the "ON position, and power up the StarSCAN(R). 3. If the WCM is electronically locked up, the StarSCAN(R) will display the WCM as being "off bus". 4. If the no crank / no start condition is present, and the WCM is "off bus", then reset the WCM by temporarily removing the IOD fuse (with the key out of the ignition switch), wait for 10 seconds and then reinstall the IOD fuse. 5. With the IOD fuse reset having been performed, verify that the vehicle will now crank, start, and run. 6. If the condition is temporarily corrected by performing the above steps, and if the part number of the WCM is earlier than the part number of the WCM listed in the part reference table in the Service Bulletin Parts Required Section below, then perform the Repair Procedure. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 5825 PARTS REQUIRED: NOTE: The part numbers listed in the following part reference table are to be used as A GUIDE to help determine if the WCM, that is currently in the vehicle, may require replacement. If it is determined that the WCM requires replacement, then ALWAYS REFER TO THE PARTS MANUAL to determine the correct WCM for the specific vehicle in question. In some earlier model years, the WCM may rule (supersede) to one of the part numbers listed in the table. ALWAYS REFER TO THE PARTS MANUAL (not the part reference table) to determine the correct part number ruling (supercedence / substitution). MAKE CERTAIN THAT THE CORRECT WCM IS ORDERED THE FIRST TIME FOR THE SPECIFIC VEHICLE IN QUESTION. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 5826 REPAIR PROCEDURE: NOTE: If the vehicle (a JS model vehicle in certain International markets) is equipped with an Electric Steering Column Lock (ELV), then the WCM and the ELV must be replaced. Replace the WCM and then the ELV. Next program the WCM and at least one (1) ignition key BEFORE programming the ELV. IMPORTANT: Not following this repair process correctly will cause the new ELV to fail. NOTE: Insert the ignition key into the ignition lock cylinder. This will move the shaft lock module locking bolt to the unlocked position. LEAVE the key in the lock cylinder while the shaft lock module is being removed. 1. If vehicle is equipped with a Steering Shaft Lock Module (JS - Avenger I Stratus - some International Markets), then the Shaft Lock Module will require replacement. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Security Information > Module, Shaft Lock > Removal and Installation. NOTE: The shaft lock module cannot be removed from the steering column while the locking bolt is in the locked position without irreversibly damaging the column. Before attempting service, the ignition key must have been inserted into the ignition lock cylinder. Then rotate the steering wheel from side to side. If the steering wheel can be rotated, the locking bolt is in the unlocked position. Leave the key in the ignition lock cylinder until shaft lock module removal has been completed. If the steering wheel cannot be rotated, test and repair the wiring circuits between the module and the ignition switch as required. If no problem is found in these circuits, the module has failed with the locking bolt in the locked position and both the module and the steering column must be replaced with new units. 2. Replace the WCM/SKREEM. Refer to TechCONNECT for detailed service information. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Service Information > Module, Sentry Key Remote Entry > Removal and Installation. NOTE: Obtain the vehicle PIN number prior to programming WCM/SKREEM or ELV. NOTE: If during the following steps the PIN number is properly entered but is rejected, then reenter the PIN number again until it is accepted. 3. After both the WCM/SKREEM and the ELV (if equipped) have been replaced, Program the WCM/SKREEM as follows: a. Turn the ignition key to the ON position, (Engine Off) b. Connect the scan tool (StarSCAN(R)) to the data link connector and turn the ignition to the RUN position, (engine off). c. Select "ECU View." d. Scroll down and select "WCM" in the list of modules. e. Select "Misc. Functions." f. Scroll to "WCM Replaced." g. Press "Start". h. Press "Next". i. Select "Show Keyboard". j. Enter the vehicle PIN number. k. Select "Next". l. Verify PIN is correct. m. Select "Next". n. Follow on-screen prompts to complete WCM function programing for Tire Pressure Monitoring (TPM) and so on. 0. Turn the ignition key to the OFF position. Wait 30 seconds. p. Turn the ignition key to the ON position, (Engine Off) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 5827 q. Select "ECU View". r. Scroll down and select "WCM" in the list of modules. s. Select "Misc. Functions." t. Select "Program Ign. Keys" and follow on-screen prompts. u. Select "Complete". v. Verify ignition key will start vehicle and the Remote Keyless Entry (RKE) functions operate. CAUTION: If the vehicle is equipped with a Shaft Lock Module (used in some International Markets on JS model vehicles), then at least one (1 ignition key must have been programmed to the new WCM BEFORE the new Shaft Lock Module is "married" to the new WCM. 4. Is the vehicle equipped with Steering Shaft Lock Module (ELV)? a. Yes >> Proceed to Step # 5. b. No >>Repair is complete. 5. Program the ELV as follows; a. Select "ECU View". b. Scroll down and select "WCM" in the list of modules. c. Select "Misc. Functions". d. Scroll to "ELV Replaced." e. Press "Start". f. When complete, verify steering shaft lock mechanism is operating. Remove and insert key from the ignition lock cylinder and listen for solenoid "click at lower end of column. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 5828 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Distribution Module: > G42 > Jan > 08 > Campaign - TIPM Software Update for Antitheft System Technical Service Bulletin # G42 Date: 080101 Campaign - TIPM Software Update for Antitheft System January 2008 Distributor/Dealer Service Instructions for: Customer Satisfaction Notice G42 TIPM Re-Configure, Anti-Theft System Models 2007 2008 (JS/PM/MK) Sebring, Avenger, Caliber, Compass and Patriot vehicles (International Markets Only) NOTE: This customer satisfaction notice applies only to the above vehicles built at the Sterling Heights Assembly Plant through July 25, 2007 (MDH 0725XX) and the Belvidere Assembly Plant through July 23, 2007 (MDH 0723XX). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this customer satisfaction notice. IMPORTANT: Some of the involved vehicles may be in distributor/dealer used vehicle inventory. Distributors/Dealers should complete this recall service on these vehicles before retail delivery. Distributors/Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Totally Integrated Power Module (TIPM) vehicles may be configured incorrectly preventing the Anti-Theft Security System from operating properly. Repair The Totally Integrated Power Module (TIPM) must be Re-Configured. Special Tools These existing special tools are required to perform this repair. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Distribution Module: > G42 > Jan > 08 > Campaign - TIPM Software Update for Antitheft System > Page 5834 Use the labor operation number and time allowance shown. Distributor/ Dealer Notification and Vehicle List Regional offices will receive an electronic list of involved vehicles. The Vehicle List is arranged by Distributor/Dealer code and in Vehicle Identification Number (VIN) sequence. The lists are for Distributor/Dealer reference in arranging for service of involved vehicles. Owner Notification and Service Scheduling All involved vehicle owners should be notified of the service requirement by their Distributor/Dealer. Owners are requested to schedule appointments for this service. A sample copy of the owner notification letter is included. Vehicle Lists, Global Recall System, VIP and Distributor/Dealer Follow up All involved vehicles have been entered into the Global Recall System (GRS) and Vehicle Information Plus (VIP) for Distributor/Dealer inquiry as needed. GRS provides involved Distributors/Dealers with an updated VIN list of their incomplete vehicles. Completed vehicles are removed from GRS within several days of repair claim submission. Distributors/Dealers must perform this repair on all unsold vehicles before retail delivery. Distributors/Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Additional Information If you have any questions or need assistance in completing this action, please contact your International Service and Parts Manager. Global Service & Parts - International Chrysler LLC Service Procedure NOTE: Use StarSCAN(R) to perform this Customer Satisfaction Notice. This procedure must be performed using software release 8.02 or higher. Re-Configure the TIPM using StarSCAN(R) 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN(R) Ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN® vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN(R). 5. Re-Configure the TIPM as Follows: a. With the StarSCAN(R) on the "Home" screen, select "ECU View". b. Select "TIPMCGW Central Gateway" in the list of modules. c. Select "Misc Functions". Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Distribution Module: > G42 > Jan > 08 > Campaign - TIPM Software Update for Antitheft System > Page 5835 d. Select "Restore Vehicle Configuration". e. Press "Start". f. Follow the prompts listed on the StarSCAN(R). g. When prompted, Enter the full 17 digit VIN found on the VIN plate. NOTE: Assure the correct VIN is input into the StarSCAN(R). h. Select "Next". NOTE: The StarSCAN(R) must be connected to the dealer network drop. i. Follow the prompts listed on the StarSCAN(R). 6. Check and clear any Diagnostic Trouble Codes (DTC's) that may have been set. 7. Turn the ignition key to the "OFF" position and remove the StarSCAN(R) unit, StarSCAN(R) cable, and battery charger from the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead Power Distribution Module: Locations Module-Electronic Overhead Component ID: 148 Component : MODULE-ELECTRONIC OVERHEAD Connector: Name : MODULE-ELECTRONIC OVERHEAD C1 Color : BLACK # of pins : 3 A READING/RAIL LAMPS DRIVER M27 20YL/LB B GROUND Z936 20BK/LB C COURTESY LAMPS DRIVER M24 20YL/WT Component Location - 43 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5838 Connector: Name : MODULE-ELECTRONIC OVERHEAD C2 Color : BLACK # of pins : 4 A SUNROOF VENT SWITCH SENSE Q4 20OR/YL B SUNROOF SWITCH SUPPLY Q6 20OR/LG C SUNROOF OPEN SWITCH SENSE Q3 20OR/TN D SUNROOF CLOSE SWITCH SENSE Q5 20OR/LB Component Location - 43 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5839 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5840 Power Distribution Module: Locations Module-Totally Integrated Power Component ID: 163 Component : MODULE-TOTALLY INTEGRATED POWER Connector: Name : MODULE-TOTALLY INTEGRATED POWER C1 Color : BLACK # of pins : 13 Pin Description Circuit 1 REAR WASHER PUMP MOTOR CONTROL W20 20BR/YL 2 FRONT WASHER PUMP MOTOR CONTROL W10 20BR/TN 3 IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4-5-6 CABIN HEATER RELAY 2 CONTROL K232 20BR/LB 7 CABIN HEATER RELAY 1 CONTROL K132 20DB/LB 8-9-10 - 11 - 12 BRAKE FLUID LEVEL SWITCH SENSE B20 20DG/RD 13 GROUND Z924 20BK/LB Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5841 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5842 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C10 Color : LT. GRAY # of pins : 8 Pin Description Circuit 1-2-3 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 4-5 FUSED MAIN RELAY OUTPUT F343 18DB/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5843 6 FUSED MAIN RELAY OUTPUT F344 18DB/LB 7-8 STARTER CONTROL OUTPUT T750 16YL/GY Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5844 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C11 Color : GREEN # of pins : 22 Pin Description Circuit 1 FUSED MAIN RELAY OUTPUT F342 14BR/DG 2-3-4 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 5 FRONT FOG LAMP CONTROL OUTPUT L89 20WT/YL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5845 6 FRONT FOG LAMP CONTROL OUTPUT L90 20WT/OR 7 LOW/HIGH RAD FAN RELAY CONTROL N201 20DB/LG 8 HORN CONTROL OUTPUT X22 20GY/LB 9 HORN CONTROL OUTPUT X21 20GY/YL 10 FRONT WIPER HIGH SPEED CONTROL OUTPUT W4 16BR/LB 11 FUSED B(+) A935 20RD/LB 12 FRONT WIPER LOW SPEED CONTROL OUTPUT W3 16BR/WT 13 FUSED IGNITION SWITCH OUTPUT (RUN) F936 20PK/YL 14 FUSED B(+) (VALVE) A922 14RD/BK 15 - 16 - - 17 FUSED B(+) (PUMP) A921 12RD/DB 18 - 19 FUSED B(+) A931 20RD/WT 20 - 21 GROUND Z971 16BK 22 RAD FAN RELAY CONTROL N112 20DB/OR Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5846 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C2 Color : LT. GRAY # of pins : 14 Pin Description Circuit 1 IGNITION SWITCH OUTPUT (UNLOCK-RUN-START) F901 20PK/RD 2 STARTER CONTROL T752 20DG/OR 3-4 FUEL PUMP CONTROL K31 20DB/BK 4 FUEL PUMP CONTROL K31 20BR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5847 5 FRONT WIPER PARK SWITCH SENSE W7 20BR/DB 6 GROUND Z924 20BK/LB 7 CAN C BUS (+) D265 20WT/BK 8-9-10 IGNITION SWITCH OUTPUT (UNLOCK-RUN-START) F901 20PK/RD 11 HOOD AJAR SWITCH SENSE G70 20VT/LB 12 - 13 GROUND Z925 20BK/YL 14 CAN C BUS (-) D264 20DB/WT Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5848 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C3 Color : BROWN # of pins : 16 Pin Description Circuit 1 CAN C BUS (+) D65 20WT/BK 2 DIAGNOSTIC CAN C (+) D72 20WT/TN 3 CAN B BUS (+) D55 20WT/OR 4 LEFT REAR TURN SIGNAL L63 20DG/RD 5-- Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5849 6 RIGHT REAR TURN SIGNAL L62 20WT/YL 7 STOP LAMP SWITCH OUTPUT L53 20DG/WT 8 PARK LAMP CONTROL OUTPUT L217 20WT/VT 9 CAN C BUS (-) D64 20WT/LB 10 DIAGNOSTIC CAN C (-) D71 20WT/DB 11 CAN B BUS (-) D54 20WT/PK 12 IGNITION SWITCH OUTPUT (START) F961 20PK/LB 13 STOP LAMP CONTROL OUTPUT L55 20WT/OR 14 - 15 RIGHT REAR WHEEL SPEED SENSOR SIGNAL B1 20YL/DB 16 RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY B2 20DG/TN Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5850 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C4 Color : BLACK # of pins : 10 Pin Description Circuit 1 LEFT TURN SIGNAL L61 20WT/RD 2 RIGHT TURN SIGNAL L60 20WT/TN 3 RIGHT HIGH BEAM OUTPUT L34 20WT/GY 4 LEFT LOW BEAM OUTPUT L43 20WT/DB 5-- Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5851 6-7-8 AAT SIGNAL G31 20VT/LG 9 AAT RETURN G931 20VT/DB 10 - Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5852 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C5 Color : BLUE # of pins : 14 Pin Description Circuit 1 HEADLAMP SWITCH OUTPUT L70 20WT/GY 2 RIGHT TURN SIGNAL (OUT) L160 20WT/TN 3 RIGHT LOW BEAM OUTPUT L44 20VT/RD 4 LEFT HIGH BEAM OUTPUT L33 20WT/PK 5 LEFT TURN SIGNAL (OUT) L161 20WT/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5853 6 HEADLAMP SWITCH OUTPUT L7 20WT/VT 6 HEADLAMP SWITCH OUTPUT L7 20WT/YL 7 A/C PRESSURE SENSOR SUPPLY C818 20LB/TN 8 BACKUP LAMP SWITCH SIGNAL T22 20YL/VT 9 HEADLAMP LEVEL SENSOR SIGNAL L131 20WT/LG 10 HEADLAMP LEVEL SENSOR SIGNAL L132 20LG/WT 11 - 12 A/C PRESSURE SENSOR SIGNAL C18 20LB/BR 13 A/C PRESSURE SENSOR GROUND C918 20BK/LB 14 IGNITION SWITCH OUTPUT (START) F962 20PK/BK Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5854 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C6 Color : LT. GRAY # of pins : 13 Pin Description Circuit 1-2-3-4-5 REAR WIPER MOTOR CONTROL W13 20BR/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5855 6-7-8-9-10 - 11 - 12 REAR FOG LAMP CONTROL OUTPUT L239 20WT/DG 13 - Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5856 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C7 Color : LT. GRAY # of pins : 22 Pin Description Circuit 1-2 FUSED B(+) A923 18RD/WT 2 FUSED B(+) A923 20RD/WT 3 FUSED B(+) A924 20DG/WT 4 FUSED B(+) A952 20RD/OR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5857 5 FUSED IGNITION SWITCH OUTPUT (RUN-START) F200 20PK/LB 6 FUSED B(+) A100 18RD/VT 7 FUSED IGNITION SWITCH OUTPUT (RUN) F100 20DG/YL 8-9 FUSED B(+) A933 20RD/LG 10 - 11 FUEL PUMP CONTROL OUTPUT N1 16DB/OR 12 - 13 FUSED B(+) (I.O.D.) A417 20RD/DG 14 - 15 FUSED B(+) (I.O.D.) A418 20RD/BK 16 FUSED B(+) (I.O.D.) A412 20RD/DB 17 FUSED B(+) A16 12RD/BR 18 DOOR LOCK POWER-FUSED B(+) A932 18RD/BR 19 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F996 20PK/YL 20 - 21 IGNITION SWITCH OUTPUT (RUN-ACC) F981 14PK/BR 22 FUSED B(+) A999 18RD/PK Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5858 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C8 Color : BLACK # of pins : 22 Pin Description Circuit 1 BLOWER MOTOR CONTROL C7 12DB/PK 2 FUSED B(+) A927 16RD/GY 3 FUSED B(+) (I.O.D.) A415 20RD/TN 4 FUSED B(+) (I.O.D.) A414 20RD/DG 5 FUSED B(+) (I.O.D.) A416 18RD Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5859 6 FUSED B(+) (I.O.D.) A420 18WT/RD 7 FUSED B(+) A14 12RD/YL 8 FUSED IGNITION SWITCH OUTPUT (RUN) F937 18PK/YL 9 FUSED REAR WINDOW DEFOGGER CONTROL OUTPUT C16 20DB/GY 10 - 11 BACKUP LAMP SWITCH OUTPUT L1 20WT/LG 12 FUSED IGNITION SWITCH OUTPUT (RUN) F929 20PK/RD 13 FUSED B(+) (I.O.D.) A411 20RD/LG 14 FUSED B(+) (I.O.D.) A419 18RD/DG 15 - 16 - - 17 REAR WINDOW DEFOGGER CONTROL OUTPUT C515 12LB/OR 18 FUSED B(+) (I.O.D.) A413 18RD/LB 19 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 20 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F985 18PK/YL 21 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F986 20PK/BK 22 MAIN RELAY OUTPUT K542 12BR/WT Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5860 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C9 Color : # of pins : 1 Pin Description Circuit 1 B(+) A0 6RD Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5861 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5862 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5863 Power Distribution Module: Locations Module-Inverter Component ID: 157 Component : MODULE-INVERTER Connector: Name : MODULE-INVERTER Color : # of pins : 9 Qualifier : (EXCEPT EXPORT) Pin Description Circuit 1 FUSED B(+) A999 16RD/PK 2-3 110 VOLT AC LINE 1 P801 18LG/PK 4 GROUND Z940 14BK/LG 5 INVERTER ENABLE SWITCH SIGNAL P805 18LG/DB 6-- 7-8 110 VOLT AC COMMON P809 18LG/LB 9-Component Location - 24 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5864 Component Location - 26 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5865 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead Power Distribution Module: Diagrams Module-Electronic Overhead Component ID: 148 Component : MODULE-ELECTRONIC OVERHEAD Connector: Name : MODULE-ELECTRONIC OVERHEAD C1 Color : BLACK # of pins : 3 A READING/RAIL LAMPS DRIVER M27 20YL/LB B GROUND Z936 20BK/LB C COURTESY LAMPS DRIVER M24 20YL/WT Component Location - 43 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 5868 Connector: Name : MODULE-ELECTRONIC OVERHEAD C2 Color : BLACK # of pins : 4 A SUNROOF VENT SWITCH SENSE Q4 20OR/YL B SUNROOF SWITCH SUPPLY Q6 20OR/LG C SUNROOF OPEN SWITCH SENSE Q3 20OR/TN D SUNROOF CLOSE SWITCH SENSE Q5 20OR/LB Component Location - 43 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 5869 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 5870 Power Distribution Module: Diagrams Module-Totally Integrated Power Component ID: 163 Component : MODULE-TOTALLY INTEGRATED POWER Connector: Name : MODULE-TOTALLY INTEGRATED POWER C1 Color : BLACK # of pins : 13 Pin Description Circuit 1 REAR WASHER PUMP MOTOR CONTROL W20 20BR/YL 2 FRONT WASHER PUMP MOTOR CONTROL W10 20BR/TN 3 IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4-5-6 CABIN HEATER RELAY 2 CONTROL K232 20BR/LB 7 CABIN HEATER RELAY 1 CONTROL K132 20DB/LB 8-9-10 - 11 - 12 BRAKE FLUID LEVEL SWITCH SENSE B20 20DG/RD 13 GROUND Z924 20BK/LB Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 5871 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 5872 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C10 Color : LT. GRAY # of pins : 8 Pin Description Circuit 1-2-3 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 4-5 FUSED MAIN RELAY OUTPUT F343 18DB/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 5873 6 FUSED MAIN RELAY OUTPUT F344 18DB/LB 7-8 STARTER CONTROL OUTPUT T750 16YL/GY Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 5874 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C11 Color : GREEN # of pins : 22 Pin Description Circuit 1 FUSED MAIN RELAY OUTPUT F342 14BR/DG 2-3-4 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 5 FRONT FOG LAMP CONTROL OUTPUT L89 20WT/YL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 5875 6 FRONT FOG LAMP CONTROL OUTPUT L90 20WT/OR 7 LOW/HIGH RAD FAN RELAY CONTROL N201 20DB/LG 8 HORN CONTROL OUTPUT X22 20GY/LB 9 HORN CONTROL OUTPUT X21 20GY/YL 10 FRONT WIPER HIGH SPEED CONTROL OUTPUT W4 16BR/LB 11 FUSED B(+) A935 20RD/LB 12 FRONT WIPER LOW SPEED CONTROL OUTPUT W3 16BR/WT 13 FUSED IGNITION SWITCH OUTPUT (RUN) F936 20PK/YL 14 FUSED B(+) (VALVE) A922 14RD/BK 15 - 16 - - 17 FUSED B(+) (PUMP) A921 12RD/DB 18 - 19 FUSED B(+) A931 20RD/WT 20 - 21 GROUND Z971 16BK 22 RAD FAN RELAY CONTROL N112 20DB/OR Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 5876 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C2 Color : LT. GRAY # of pins : 14 Pin Description Circuit 1 IGNITION SWITCH OUTPUT (UNLOCK-RUN-START) F901 20PK/RD 2 STARTER CONTROL T752 20DG/OR 3-4 FUEL PUMP CONTROL K31 20DB/BK 4 FUEL PUMP CONTROL K31 20BR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 5877 5 FRONT WIPER PARK SWITCH SENSE W7 20BR/DB 6 GROUND Z924 20BK/LB 7 CAN C BUS (+) D265 20WT/BK 8-9-10 IGNITION SWITCH OUTPUT (UNLOCK-RUN-START) F901 20PK/RD 11 HOOD AJAR SWITCH SENSE G70 20VT/LB 12 - 13 GROUND Z925 20BK/YL 14 CAN C BUS (-) D264 20DB/WT Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 5878 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C3 Color : BROWN # of pins : 16 Pin Description Circuit 1 CAN C BUS (+) D65 20WT/BK 2 DIAGNOSTIC CAN C (+) D72 20WT/TN 3 CAN B BUS (+) D55 20WT/OR 4 LEFT REAR TURN SIGNAL L63 20DG/RD 5-- Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 5879 6 RIGHT REAR TURN SIGNAL L62 20WT/YL 7 STOP LAMP SWITCH OUTPUT L53 20DG/WT 8 PARK LAMP CONTROL OUTPUT L217 20WT/VT 9 CAN C BUS (-) D64 20WT/LB 10 DIAGNOSTIC CAN C (-) D71 20WT/DB 11 CAN B BUS (-) D54 20WT/PK 12 IGNITION SWITCH OUTPUT (START) F961 20PK/LB 13 STOP LAMP CONTROL OUTPUT L55 20WT/OR 14 - 15 RIGHT REAR WHEEL SPEED SENSOR SIGNAL B1 20YL/DB 16 RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY B2 20DG/TN Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 5880 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C4 Color : BLACK # of pins : 10 Pin Description Circuit 1 LEFT TURN SIGNAL L61 20WT/RD 2 RIGHT TURN SIGNAL L60 20WT/TN 3 RIGHT HIGH BEAM OUTPUT L34 20WT/GY 4 LEFT LOW BEAM OUTPUT L43 20WT/DB 5-- Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 5881 6-7-8 AAT SIGNAL G31 20VT/LG 9 AAT RETURN G931 20VT/DB 10 - Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 5882 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C5 Color : BLUE # of pins : 14 Pin Description Circuit 1 HEADLAMP SWITCH OUTPUT L70 20WT/GY 2 RIGHT TURN SIGNAL (OUT) L160 20WT/TN 3 RIGHT LOW BEAM OUTPUT L44 20VT/RD 4 LEFT HIGH BEAM OUTPUT L33 20WT/PK 5 LEFT TURN SIGNAL (OUT) L161 20WT/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 5883 6 HEADLAMP SWITCH OUTPUT L7 20WT/VT 6 HEADLAMP SWITCH OUTPUT L7 20WT/YL 7 A/C PRESSURE SENSOR SUPPLY C818 20LB/TN 8 BACKUP LAMP SWITCH SIGNAL T22 20YL/VT 9 HEADLAMP LEVEL SENSOR SIGNAL L131 20WT/LG 10 HEADLAMP LEVEL SENSOR SIGNAL L132 20LG/WT 11 - 12 A/C PRESSURE SENSOR SIGNAL C18 20LB/BR 13 A/C PRESSURE SENSOR GROUND C918 20BK/LB 14 IGNITION SWITCH OUTPUT (START) F962 20PK/BK Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 5884 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C6 Color : LT. GRAY # of pins : 13 Pin Description Circuit 1-2-3-4-5 REAR WIPER MOTOR CONTROL W13 20BR/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 5885 6-7-8-9-10 - 11 - 12 REAR FOG LAMP CONTROL OUTPUT L239 20WT/DG 13 - Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 5886 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C7 Color : LT. GRAY # of pins : 22 Pin Description Circuit 1-2 FUSED B(+) A923 18RD/WT 2 FUSED B(+) A923 20RD/WT 3 FUSED B(+) A924 20DG/WT 4 FUSED B(+) A952 20RD/OR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 5887 5 FUSED IGNITION SWITCH OUTPUT (RUN-START) F200 20PK/LB 6 FUSED B(+) A100 18RD/VT 7 FUSED IGNITION SWITCH OUTPUT (RUN) F100 20DG/YL 8-9 FUSED B(+) A933 20RD/LG 10 - 11 FUEL PUMP CONTROL OUTPUT N1 16DB/OR 12 - 13 FUSED B(+) (I.O.D.) A417 20RD/DG 14 - 15 FUSED B(+) (I.O.D.) A418 20RD/BK 16 FUSED B(+) (I.O.D.) A412 20RD/DB 17 FUSED B(+) A16 12RD/BR 18 DOOR LOCK POWER-FUSED B(+) A932 18RD/BR 19 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F996 20PK/YL 20 - 21 IGNITION SWITCH OUTPUT (RUN-ACC) F981 14PK/BR 22 FUSED B(+) A999 18RD/PK Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 5888 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C8 Color : BLACK # of pins : 22 Pin Description Circuit 1 BLOWER MOTOR CONTROL C7 12DB/PK 2 FUSED B(+) A927 16RD/GY 3 FUSED B(+) (I.O.D.) A415 20RD/TN 4 FUSED B(+) (I.O.D.) A414 20RD/DG 5 FUSED B(+) (I.O.D.) A416 18RD Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 5889 6 FUSED B(+) (I.O.D.) A420 18WT/RD 7 FUSED B(+) A14 12RD/YL 8 FUSED IGNITION SWITCH OUTPUT (RUN) F937 18PK/YL 9 FUSED REAR WINDOW DEFOGGER CONTROL OUTPUT C16 20DB/GY 10 - 11 BACKUP LAMP SWITCH OUTPUT L1 20WT/LG 12 FUSED IGNITION SWITCH OUTPUT (RUN) F929 20PK/RD 13 FUSED B(+) (I.O.D.) A411 20RD/LG 14 FUSED B(+) (I.O.D.) A419 18RD/DG 15 - 16 - - 17 REAR WINDOW DEFOGGER CONTROL OUTPUT C515 12LB/OR 18 FUSED B(+) (I.O.D.) A413 18RD/LB 19 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 20 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F985 18PK/YL 21 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F986 20PK/BK 22 MAIN RELAY OUTPUT K542 12BR/WT Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 5890 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C9 Color : # of pins : 1 Pin Description Circuit 1 B(+) A0 6RD Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 5891 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 5892 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 5893 Power Distribution Module: Diagrams Module-Inverter Component ID: 157 Component : MODULE-INVERTER Connector: Name : MODULE-INVERTER Color : # of pins : 9 Qualifier : (EXCEPT EXPORT) Pin Description Circuit 1 FUSED B(+) A999 16RD/PK 2-3 110 VOLT AC LINE 1 P801 18LG/PK 4 GROUND Z940 14BK/LG 5 INVERTER ENABLE SWITCH SIGNAL P805 18LG/DB 6-- 7-8 110 VOLT AC COMMON P809 18LG/LB 9-Component Location - 24 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 5894 Component Location - 26 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 5895 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Totally Integrated Power Module Power Distribution Module: Description and Operation Totally Integrated Power Module Description DESCRIPTION All of the electrical current distributed throughout this vehicle is directed through the standard equipment Totally Integrated Power Module (TIPM) (1). The molded plastic TIPM housing is located in the left front corner of the engine compartment, just behind the air cleaner housing and the battery. The TIPM housing has a molded plastic cover. The TIPM cover is easily removed for service access and has a convenient fuse and relay layout label affixed to the inside surface of the cover to ensure proper component identification. The TIPM housing is secured to the left inner fender well an indexing pin and one screw. All of the TIPM outputs are through the integral engine compartment wire harness. Operation OPERATION All of the current from the generator cable connection goes to the battery through a 10 gauge fusible link that is secured with a nut to the positive battery terminal at the starter. Internal connection of all the Totally Integrated Power Module (TIPM) circuits is accomplished by an intricate network of hard wiring and bus bars. Refer to Wiring Diagrams for complete circuit diagrams. The fusible link, fuses and relays are available for service replacement. The TIPM unit cannot be repaired and is only serviced as a unit with the engine compartment wire harness. If the TIPM is inoperative or damaged, the engine compartment wire harness assembly must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Totally Integrated Power Module > Page 5898 Power Distribution Module: Description and Operation Module-Inverter Description DESCRIPTION The inverter module is located in the instrument panel. The A/C outlet is mounted in the center console. The inverter module provides A/C power for user accessories. The inverter converts the 12 Volt DC from the battery system to a 110 Volt AC output. Operation OPERATION The AC power outlet receives 12 volts from the Totally Integrated Power Module (TIPM) and passes it as an enable signal to the inverter module. The inverter module also receives 12 volts via the TIPM and inverts this to a 110 volt AC output. The enable signal received from the power outlet enables the inverter to convert the received voltage and pass it to the power outlet to power external devices. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Page 5899 Power Distribution Module: Testing and Inspection Inverter Module For complete circuit diagrams, refer to the appropriate wiring information. WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Totally Integrated Power Module Power Distribution Module: Service and Repair Totally Integrated Power Module Removal REMOVAL The TIPM (TIPM) is serviced as a unit with the engine compartment wire harness. If any internal circuit of the TIPM or the TIPM housing is faulty or damaged, the entire TIPM and engine compartment wire harness unit must be replaced. Refer to Wiring Diagrams for the locations of the affected connectors. 1. Open hood. 2. Disconnect and isolate the battery negative cable. 3. Disconnect each of the engine compartment wire harness connectors. 4. Remove the fasteners that secure each of the engine compartment wire harness ground eyelets to the vehicle body and chassis components. 5. Disengage each of the retainers that secure the engine compartment wire harness to the vehicle body and chassis components. 6. Disengage and remove the TIPM housing from its mounting bracket. 7. Remove the TIPM and the engine compartment wire harness from the engine compartment as a unit. Installation INSTALLATION The Totally Integrated Power Module (TIPM) is serviced as a unit with the engine compartment wire harness. If any internal circuit of the TIPM or the TIPM housing is faulty or damaged, the entire TIPM and engine compartment wire harness unit must be replaced. NOTE: If the Totally Integrated Power Module (TIPM) is being replaced with a new unit, be certain to transfer each of the fuses and relays from the old TIPM to the proper cavities of the new TIPM. Refer to Wiring Diagrams for the proper TIPM cavity assignments. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Totally Integrated Power Module > Page 5902 1. Position the TIPM in the engine compartment. 2. Align the TIPM on its mounting bracket and install. 3. Route the engine compartment wire harness from the TIPM through the engine compartment, engaging each of the harness retainers to the mounting provisions in the vehicle body and chassis components. Refer to Wiring Diagrams for the harness routing and retainer locations. 4. Install and tighten the fasteners that secure each of the engine compartment wire harness ground eyelets to the vehicle body and chassis components. Refer to Wiring Diagrams for the ground eyelet locations. 5. Reconnect each of the engine compartment wire harness connectors. Refer to Wiring Diagrams for the locations of the affected connectors. 6. Torque nut retaining positive battery cable at TIPM to 96 - 141 Nm (85 - 130 in. lbs.). 7. Reconnect the battery negative cable. 8. Close hood. 9. Verify vehicle and system operation. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Totally Integrated Power Module > Page 5903 Power Distribution Module: Service and Repair Module-Inverter Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. 1. Disconnect and isolate the negative battery cable. 2. Remove the shift bezel. 3. Remove the center bezel from the instrument panel. 4. Remove the fasteners from the mounting brackets of the inverter module. 5. Disconnect the electrical connectors and remove the inverter module. Installation INSTALLATION 1. Connect the electrical connectors to the inverter module. 2. Install the fasteners to the mounting brackets. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Totally Integrated Power Module > Page 5904 3. Install the center bezel to the instrument panel. 4. Install the shift bezel. 5. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Removal Power Distribution Relay: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove cover from Totally Integrated Power module (TIPM). 3. Using special tool C-4817 (1), grip the relay (2) by the sides and pull upward with an even effort. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Removal > Page 5909 Power Distribution Relay: Service and Repair Installation INSTALLATION 1. Align relay (2) with Totally Integrated Power Module (TIPM) and press into position. 2. Install cover to TIPM. 3. Connect battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Interrupt Connector/Switch > Component Information > Description and Operation > Description Power Interrupt Connector/Switch: Description and Operation Description DESCRIPTION All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is disconnected within the Totally Integrated Power Module (TIPM) when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the TIPM as part of the preparation procedures performed just prior to new vehicle delivery. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Interrupt Connector/Switch > Component Information > Description and Operation > Description > Page 5914 Power Interrupt Connector/Switch: Description and Operation Operation OPERATION The term ignition-off draw identifies a normal condition where power is being drained from the battery with the ignition switch in the Off position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the Off position, including the clock. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is disconnected from Totally Integrated Power Module (TIPM) fuse cavities 7 and 8 in a preset fuse holder. when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse serves no useful purpose to the dealer technician in the service or diagnosis of any vehicle system or condition, other than the same purpose as that of any other standard circuit protection device. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Interrupt Connector/Switch > Component Information > Service and Repair > Removal Power Interrupt Connector/Switch: Service and Repair Removal REMOVAL NOTE: When removing or installing the IOD fuse, it is important that the ignition switch be in the Off position. Failure to place the ignition switch in the Off position can cause the radio display to become scrambled when the IOD fuse is installed. Removing and installing the IOD fuse again with the ignition switch in the Off position will usually correct the scrambled radio display condition. 1. Turn the ignition switch to the Off position. 2. Remove the cover from the Totally Integrated Power Module (TIPM). 3. Remove fuse 7/8 from the TIPM. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Interrupt Connector/Switch > Component Information > Service and Repair > Removal > Page 5917 Power Interrupt Connector/Switch: Service and Repair Installation INSTALLATION CAUTION: It is extremely important that the Ignition Off Draw (IOD) fuses are fully seated into the Totally Integrated Power Module (TIPM) fuse cavities. Failure to install the fuses correctly could result in erratic electrical systems behavior. 1. Remove TIPM cover. 2. Insert fuse 7/8 into the TIPM. Push fuses down until they are fully seated in the TIPM cavities. 3. Install the cover to the TIPM. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Service and Repair > Removal Mini ISO Relay: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove cover from Totally Integrated Power module (TIPM). 3. Using special tool C-4817 (1), grip the relay (2) by the sides and pull upward with an even effort. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Service and Repair > Removal > Page 5923 Mini ISO Relay: Service and Repair Installation INSTALLATION 1. Align relay (2) with Totally Integrated Power Module (TIPM) and press into position. 2. Install cover to TIPM. 3. Connect battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Recalls: > G42 > Jan > 08 > Campaign - TIPM Software Update for Antitheft System Technical Service Bulletin # G42 Date: 080101 Campaign - TIPM Software Update for Antitheft System January 2008 Distributor/Dealer Service Instructions for: Customer Satisfaction Notice G42 TIPM Re-Configure, Anti-Theft System Models 2007 2008 (JS/PM/MK) Sebring, Avenger, Caliber, Compass and Patriot vehicles (International Markets Only) NOTE: This customer satisfaction notice applies only to the above vehicles built at the Sterling Heights Assembly Plant through July 25, 2007 (MDH 0725XX) and the Belvidere Assembly Plant through July 23, 2007 (MDH 0723XX). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this customer satisfaction notice. IMPORTANT: Some of the involved vehicles may be in distributor/dealer used vehicle inventory. Distributors/Dealers should complete this recall service on these vehicles before retail delivery. Distributors/Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Totally Integrated Power Module (TIPM) vehicles may be configured incorrectly preventing the Anti-Theft Security System from operating properly. Repair The Totally Integrated Power Module (TIPM) must be Re-Configured. Special Tools These existing special tools are required to perform this repair. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Recalls: > G42 > Jan > 08 > Campaign - TIPM Software Update for Antitheft System > Page 5932 Use the labor operation number and time allowance shown. Distributor/ Dealer Notification and Vehicle List Regional offices will receive an electronic list of involved vehicles. The Vehicle List is arranged by Distributor/Dealer code and in Vehicle Identification Number (VIN) sequence. The lists are for Distributor/Dealer reference in arranging for service of involved vehicles. Owner Notification and Service Scheduling All involved vehicle owners should be notified of the service requirement by their Distributor/Dealer. Owners are requested to schedule appointments for this service. A sample copy of the owner notification letter is included. Vehicle Lists, Global Recall System, VIP and Distributor/Dealer Follow up All involved vehicles have been entered into the Global Recall System (GRS) and Vehicle Information Plus (VIP) for Distributor/Dealer inquiry as needed. GRS provides involved Distributors/Dealers with an updated VIN list of their incomplete vehicles. Completed vehicles are removed from GRS within several days of repair claim submission. Distributors/Dealers must perform this repair on all unsold vehicles before retail delivery. Distributors/Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Additional Information If you have any questions or need assistance in completing this action, please contact your International Service and Parts Manager. Global Service & Parts - International Chrysler LLC Service Procedure NOTE: Use StarSCAN(R) to perform this Customer Satisfaction Notice. This procedure must be performed using software release 8.02 or higher. Re-Configure the TIPM using StarSCAN(R) 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN(R) Ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN® vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN(R). 5. Re-Configure the TIPM as Follows: a. With the StarSCAN(R) on the "Home" screen, select "ECU View". b. Select "TIPMCGW Central Gateway" in the list of modules. c. Select "Misc Functions". Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Recalls: > G42 > Jan > 08 > Campaign - TIPM Software Update for Antitheft System > Page 5933 d. Select "Restore Vehicle Configuration". e. Press "Start". f. Follow the prompts listed on the StarSCAN(R). g. When prompted, Enter the full 17 digit VIN found on the VIN plate. NOTE: Assure the correct VIN is input into the StarSCAN(R). h. Select "Next". NOTE: The StarSCAN(R) must be connected to the dealer network drop. i. Follow the prompts listed on the StarSCAN(R). 6. Check and clear any Diagnostic Trouble Codes (DTC's) that may have been set. 7. Turn the ignition key to the "OFF" position and remove the StarSCAN(R) unit, StarSCAN(R) cable, and battery charger from the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition Power Distribution Module: Customer Interest Antitheft System - Engine No Crank/No Start Condition NUMBER: 08-007-08 REV. A GROUP: Electrical DATE: July 04,2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-007-08, DATED MARCH 04, 2008. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. DO NOT ORDER PART NUMBER 05026070AP UNTIL JULY 21, 2008. ALL OTHER PART NUMBERS ARE AVAILABLE NOW. SUBJECT: No Engine Crank Or No Engine Start Due To Electronic Lockup Of The WCM / SKREEM OVERVIEW: This bulletin involves the replacement of the Wireless Control Module (WCM), and if equipped, the replacement of the Electric Steering Column Lock (ELV). The WCM is also referred to as the Sentry Key Remote Entry Module (SKREEM). MODELS: 2007 - 2008 (DR/DH/D1/DC/DM) Ram Truck (1500/2500/3500/4500/5500) 2007 - 2008 (JK) Wrangler 2007 - 2008 (J1) Sebring (China) 2007 - 2008 (JS) Avenger/Sebring 2007 - 2008 (KA) Nitro 2008 (KK) Liberty/Cherokee 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber 2006 - 2008 (PT) Chrysler PT Cruiser NOTE: This bulletin applies to vehicles built on or before May 05, 2008 (MDH 0505XX). SYMPTOM/CONDITION: The customer will experience a no engine crank AND a no engine start condition. Also, the remote keyless entry (RKE) system will not operate. This condition may be due to an electrostatic discharge (ESD) from the ignition key into the Wireless Control Module (WCM), causing the WCM to electronically lockup. This condition may occur more frequently in dry and/or cold weather conditions where a sufficient electrostatic charge is more easily produced. This condition is corrected by the replacement of the WCM. DIAGNOSIS: 1. With the condition present (i.e. the vehicle in the no crank / no start condition), connect the StarSCAN(R) scan tool to the vehicle. 2. Turn the ignition switch to the "ON position, and power up the StarSCAN(R). 3. If the WCM is electronically locked up, the StarSCAN(R) will display the WCM as being "off bus". 4. If the no crank / no start condition is present, and the WCM is "off bus", then reset the WCM by temporarily removing the IOD fuse (with the key out of the ignition switch), wait for 10 seconds and then reinstall the IOD fuse. 5. With the IOD fuse reset having been performed, verify that the vehicle will now crank, start, and run. 6. If the condition is temporarily corrected by performing the above steps, and if the part number of the WCM is earlier than the part number of the WCM listed in the part reference table in the Service Bulletin Parts Required Section below, then perform the Repair Procedure. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 5939 PARTS REQUIRED: NOTE: The part numbers listed in the following part reference table are to be used as A GUIDE to help determine if the WCM, that is currently in the vehicle, may require replacement. If it is determined that the WCM requires replacement, then ALWAYS REFER TO THE PARTS MANUAL to determine the correct WCM for the specific vehicle in question. In some earlier model years, the WCM may rule (supersede) to one of the part numbers listed in the table. ALWAYS REFER TO THE PARTS MANUAL (not the part reference table) to determine the correct part number ruling (supercedence / substitution). MAKE CERTAIN THAT THE CORRECT WCM IS ORDERED THE FIRST TIME FOR THE SPECIFIC VEHICLE IN QUESTION. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 5940 REPAIR PROCEDURE: NOTE: If the vehicle (a JS model vehicle in certain International markets) is equipped with an Electric Steering Column Lock (ELV), then the WCM and the ELV must be replaced. Replace the WCM and then the ELV. Next program the WCM and at least one (1) ignition key BEFORE programming the ELV. IMPORTANT: Not following this repair process correctly will cause the new ELV to fail. NOTE: Insert the ignition key into the ignition lock cylinder. This will move the shaft lock module locking bolt to the unlocked position. LEAVE the key in the lock cylinder while the shaft lock module is being removed. 1. If vehicle is equipped with a Steering Shaft Lock Module (JS - Avenger I Stratus - some International Markets), then the Shaft Lock Module will require replacement. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Security Information > Module, Shaft Lock > Removal and Installation. NOTE: The shaft lock module cannot be removed from the steering column while the locking bolt is in the locked position without irreversibly damaging the column. Before attempting service, the ignition key must have been inserted into the ignition lock cylinder. Then rotate the steering wheel from side to side. If the steering wheel can be rotated, the locking bolt is in the unlocked position. Leave the key in the ignition lock cylinder until shaft lock module removal has been completed. If the steering wheel cannot be rotated, test and repair the wiring circuits between the module and the ignition switch as required. If no problem is found in these circuits, the module has failed with the locking bolt in the locked position and both the module and the steering column must be replaced with new units. 2. Replace the WCM/SKREEM. Refer to TechCONNECT for detailed service information. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Service Information > Module, Sentry Key Remote Entry > Removal and Installation. NOTE: Obtain the vehicle PIN number prior to programming WCM/SKREEM or ELV. NOTE: If during the following steps the PIN number is properly entered but is rejected, then reenter the PIN number again until it is accepted. 3. After both the WCM/SKREEM and the ELV (if equipped) have been replaced, Program the WCM/SKREEM as follows: a. Turn the ignition key to the ON position, (Engine Off) b. Connect the scan tool (StarSCAN(R)) to the data link connector and turn the ignition to the RUN position, (engine off). c. Select "ECU View." d. Scroll down and select "WCM" in the list of modules. e. Select "Misc. Functions." f. Scroll to "WCM Replaced." g. Press "Start". h. Press "Next". i. Select "Show Keyboard". j. Enter the vehicle PIN number. k. Select "Next". l. Verify PIN is correct. m. Select "Next". n. Follow on-screen prompts to complete WCM function programing for Tire Pressure Monitoring (TPM) and so on. 0. Turn the ignition key to the OFF position. Wait 30 seconds. p. Turn the ignition key to the ON position, (Engine Off) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 5941 q. Select "ECU View". r. Scroll down and select "WCM" in the list of modules. s. Select "Misc. Functions." t. Select "Program Ign. Keys" and follow on-screen prompts. u. Select "Complete". v. Verify ignition key will start vehicle and the Remote Keyless Entry (RKE) functions operate. CAUTION: If the vehicle is equipped with a Shaft Lock Module (used in some International Markets on JS model vehicles), then at least one (1 ignition key must have been programmed to the new WCM BEFORE the new Shaft Lock Module is "married" to the new WCM. 4. Is the vehicle equipped with Steering Shaft Lock Module (ELV)? a. Yes >> Proceed to Step # 5. b. No >>Repair is complete. 5. Program the ELV as follows; a. Select "ECU View". b. Scroll down and select "WCM" in the list of modules. c. Select "Misc. Functions". d. Scroll to "ELV Replaced." e. Press "Start". f. When complete, verify steering shaft lock mechanism is operating. Remove and insert key from the ignition lock cylinder and listen for solenoid "click at lower end of column. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 5942 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition Power Distribution Module: All Technical Service Bulletins Antitheft System - Engine No Crank/No Start Condition NUMBER: 08-007-08 REV. A GROUP: Electrical DATE: July 04,2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-007-08, DATED MARCH 04, 2008. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. DO NOT ORDER PART NUMBER 05026070AP UNTIL JULY 21, 2008. ALL OTHER PART NUMBERS ARE AVAILABLE NOW. SUBJECT: No Engine Crank Or No Engine Start Due To Electronic Lockup Of The WCM / SKREEM OVERVIEW: This bulletin involves the replacement of the Wireless Control Module (WCM), and if equipped, the replacement of the Electric Steering Column Lock (ELV). The WCM is also referred to as the Sentry Key Remote Entry Module (SKREEM). MODELS: 2007 - 2008 (DR/DH/D1/DC/DM) Ram Truck (1500/2500/3500/4500/5500) 2007 - 2008 (JK) Wrangler 2007 - 2008 (J1) Sebring (China) 2007 - 2008 (JS) Avenger/Sebring 2007 - 2008 (KA) Nitro 2008 (KK) Liberty/Cherokee 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber 2006 - 2008 (PT) Chrysler PT Cruiser NOTE: This bulletin applies to vehicles built on or before May 05, 2008 (MDH 0505XX). SYMPTOM/CONDITION: The customer will experience a no engine crank AND a no engine start condition. Also, the remote keyless entry (RKE) system will not operate. This condition may be due to an electrostatic discharge (ESD) from the ignition key into the Wireless Control Module (WCM), causing the WCM to electronically lockup. This condition may occur more frequently in dry and/or cold weather conditions where a sufficient electrostatic charge is more easily produced. This condition is corrected by the replacement of the WCM. DIAGNOSIS: 1. With the condition present (i.e. the vehicle in the no crank / no start condition), connect the StarSCAN(R) scan tool to the vehicle. 2. Turn the ignition switch to the "ON position, and power up the StarSCAN(R). 3. If the WCM is electronically locked up, the StarSCAN(R) will display the WCM as being "off bus". 4. If the no crank / no start condition is present, and the WCM is "off bus", then reset the WCM by temporarily removing the IOD fuse (with the key out of the ignition switch), wait for 10 seconds and then reinstall the IOD fuse. 5. With the IOD fuse reset having been performed, verify that the vehicle will now crank, start, and run. 6. If the condition is temporarily corrected by performing the above steps, and if the part number of the WCM is earlier than the part number of the WCM listed in the part reference table in the Service Bulletin Parts Required Section below, then perform the Repair Procedure. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 5948 PARTS REQUIRED: NOTE: The part numbers listed in the following part reference table are to be used as A GUIDE to help determine if the WCM, that is currently in the vehicle, may require replacement. If it is determined that the WCM requires replacement, then ALWAYS REFER TO THE PARTS MANUAL to determine the correct WCM for the specific vehicle in question. In some earlier model years, the WCM may rule (supersede) to one of the part numbers listed in the table. ALWAYS REFER TO THE PARTS MANUAL (not the part reference table) to determine the correct part number ruling (supercedence / substitution). MAKE CERTAIN THAT THE CORRECT WCM IS ORDERED THE FIRST TIME FOR THE SPECIFIC VEHICLE IN QUESTION. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 5949 REPAIR PROCEDURE: NOTE: If the vehicle (a JS model vehicle in certain International markets) is equipped with an Electric Steering Column Lock (ELV), then the WCM and the ELV must be replaced. Replace the WCM and then the ELV. Next program the WCM and at least one (1) ignition key BEFORE programming the ELV. IMPORTANT: Not following this repair process correctly will cause the new ELV to fail. NOTE: Insert the ignition key into the ignition lock cylinder. This will move the shaft lock module locking bolt to the unlocked position. LEAVE the key in the lock cylinder while the shaft lock module is being removed. 1. If vehicle is equipped with a Steering Shaft Lock Module (JS - Avenger I Stratus - some International Markets), then the Shaft Lock Module will require replacement. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Security Information > Module, Shaft Lock > Removal and Installation. NOTE: The shaft lock module cannot be removed from the steering column while the locking bolt is in the locked position without irreversibly damaging the column. Before attempting service, the ignition key must have been inserted into the ignition lock cylinder. Then rotate the steering wheel from side to side. If the steering wheel can be rotated, the locking bolt is in the unlocked position. Leave the key in the ignition lock cylinder until shaft lock module removal has been completed. If the steering wheel cannot be rotated, test and repair the wiring circuits between the module and the ignition switch as required. If no problem is found in these circuits, the module has failed with the locking bolt in the locked position and both the module and the steering column must be replaced with new units. 2. Replace the WCM/SKREEM. Refer to TechCONNECT for detailed service information. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Service Information > Module, Sentry Key Remote Entry > Removal and Installation. NOTE: Obtain the vehicle PIN number prior to programming WCM/SKREEM or ELV. NOTE: If during the following steps the PIN number is properly entered but is rejected, then reenter the PIN number again until it is accepted. 3. After both the WCM/SKREEM and the ELV (if equipped) have been replaced, Program the WCM/SKREEM as follows: a. Turn the ignition key to the ON position, (Engine Off) b. Connect the scan tool (StarSCAN(R)) to the data link connector and turn the ignition to the RUN position, (engine off). c. Select "ECU View." d. Scroll down and select "WCM" in the list of modules. e. Select "Misc. Functions." f. Scroll to "WCM Replaced." g. Press "Start". h. Press "Next". i. Select "Show Keyboard". j. Enter the vehicle PIN number. k. Select "Next". l. Verify PIN is correct. m. Select "Next". n. Follow on-screen prompts to complete WCM function programing for Tire Pressure Monitoring (TPM) and so on. 0. Turn the ignition key to the OFF position. Wait 30 seconds. p. Turn the ignition key to the ON position, (Engine Off) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 5950 q. Select "ECU View". r. Scroll down and select "WCM" in the list of modules. s. Select "Misc. Functions." t. Select "Program Ign. Keys" and follow on-screen prompts. u. Select "Complete". v. Verify ignition key will start vehicle and the Remote Keyless Entry (RKE) functions operate. CAUTION: If the vehicle is equipped with a Shaft Lock Module (used in some International Markets on JS model vehicles), then at least one (1 ignition key must have been programmed to the new WCM BEFORE the new Shaft Lock Module is "married" to the new WCM. 4. Is the vehicle equipped with Steering Shaft Lock Module (ELV)? a. Yes >> Proceed to Step # 5. b. No >>Repair is complete. 5. Program the ELV as follows; a. Select "ECU View". b. Scroll down and select "WCM" in the list of modules. c. Select "Misc. Functions". d. Scroll to "ELV Replaced." e. Press "Start". f. When complete, verify steering shaft lock mechanism is operating. Remove and insert key from the ignition lock cylinder and listen for solenoid "click at lower end of column. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 5951 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > G42 > Jan > 08 > Campaign - TIPM Software Update for Antitheft System Technical Service Bulletin # G42 Date: 080101 Campaign - TIPM Software Update for Antitheft System January 2008 Distributor/Dealer Service Instructions for: Customer Satisfaction Notice G42 TIPM Re-Configure, Anti-Theft System Models 2007 2008 (JS/PM/MK) Sebring, Avenger, Caliber, Compass and Patriot vehicles (International Markets Only) NOTE: This customer satisfaction notice applies only to the above vehicles built at the Sterling Heights Assembly Plant through July 25, 2007 (MDH 0725XX) and the Belvidere Assembly Plant through July 23, 2007 (MDH 0723XX). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this customer satisfaction notice. IMPORTANT: Some of the involved vehicles may be in distributor/dealer used vehicle inventory. Distributors/Dealers should complete this recall service on these vehicles before retail delivery. Distributors/Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Totally Integrated Power Module (TIPM) vehicles may be configured incorrectly preventing the Anti-Theft Security System from operating properly. Repair The Totally Integrated Power Module (TIPM) must be Re-Configured. Special Tools These existing special tools are required to perform this repair. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > G42 > Jan > 08 > Campaign - TIPM Software Update for Antitheft System > Page 5956 Use the labor operation number and time allowance shown. Distributor/ Dealer Notification and Vehicle List Regional offices will receive an electronic list of involved vehicles. The Vehicle List is arranged by Distributor/Dealer code and in Vehicle Identification Number (VIN) sequence. The lists are for Distributor/Dealer reference in arranging for service of involved vehicles. Owner Notification and Service Scheduling All involved vehicle owners should be notified of the service requirement by their Distributor/Dealer. Owners are requested to schedule appointments for this service. A sample copy of the owner notification letter is included. Vehicle Lists, Global Recall System, VIP and Distributor/Dealer Follow up All involved vehicles have been entered into the Global Recall System (GRS) and Vehicle Information Plus (VIP) for Distributor/Dealer inquiry as needed. GRS provides involved Distributors/Dealers with an updated VIN list of their incomplete vehicles. Completed vehicles are removed from GRS within several days of repair claim submission. Distributors/Dealers must perform this repair on all unsold vehicles before retail delivery. Distributors/Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Additional Information If you have any questions or need assistance in completing this action, please contact your International Service and Parts Manager. Global Service & Parts - International Chrysler LLC Service Procedure NOTE: Use StarSCAN(R) to perform this Customer Satisfaction Notice. This procedure must be performed using software release 8.02 or higher. Re-Configure the TIPM using StarSCAN(R) 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN(R) Ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN® vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN(R). 5. Re-Configure the TIPM as Follows: a. With the StarSCAN(R) on the "Home" screen, select "ECU View". b. Select "TIPMCGW Central Gateway" in the list of modules. c. Select "Misc Functions". Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > G42 > Jan > 08 > Campaign - TIPM Software Update for Antitheft System > Page 5957 d. Select "Restore Vehicle Configuration". e. Press "Start". f. Follow the prompts listed on the StarSCAN(R). g. When prompted, Enter the full 17 digit VIN found on the VIN plate. NOTE: Assure the correct VIN is input into the StarSCAN(R). h. Select "Next". NOTE: The StarSCAN(R) must be connected to the dealer network drop. i. Follow the prompts listed on the StarSCAN(R). 6. Check and clear any Diagnostic Trouble Codes (DTC's) that may have been set. 7. Turn the ignition key to the "OFF" position and remove the StarSCAN(R) unit, StarSCAN(R) cable, and battery charger from the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition Power Distribution Module: All Technical Service Bulletins Antitheft System - Engine No Crank/No Start Condition NUMBER: 08-007-08 REV. A GROUP: Electrical DATE: July 04,2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-007-08, DATED MARCH 04, 2008. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. DO NOT ORDER PART NUMBER 05026070AP UNTIL JULY 21, 2008. ALL OTHER PART NUMBERS ARE AVAILABLE NOW. SUBJECT: No Engine Crank Or No Engine Start Due To Electronic Lockup Of The WCM / SKREEM OVERVIEW: This bulletin involves the replacement of the Wireless Control Module (WCM), and if equipped, the replacement of the Electric Steering Column Lock (ELV). The WCM is also referred to as the Sentry Key Remote Entry Module (SKREEM). MODELS: 2007 - 2008 (DR/DH/D1/DC/DM) Ram Truck (1500/2500/3500/4500/5500) 2007 - 2008 (JK) Wrangler 2007 - 2008 (J1) Sebring (China) 2007 - 2008 (JS) Avenger/Sebring 2007 - 2008 (KA) Nitro 2008 (KK) Liberty/Cherokee 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber 2006 - 2008 (PT) Chrysler PT Cruiser NOTE: This bulletin applies to vehicles built on or before May 05, 2008 (MDH 0505XX). SYMPTOM/CONDITION: The customer will experience a no engine crank AND a no engine start condition. Also, the remote keyless entry (RKE) system will not operate. This condition may be due to an electrostatic discharge (ESD) from the ignition key into the Wireless Control Module (WCM), causing the WCM to electronically lockup. This condition may occur more frequently in dry and/or cold weather conditions where a sufficient electrostatic charge is more easily produced. This condition is corrected by the replacement of the WCM. DIAGNOSIS: 1. With the condition present (i.e. the vehicle in the no crank / no start condition), connect the StarSCAN(R) scan tool to the vehicle. 2. Turn the ignition switch to the "ON position, and power up the StarSCAN(R). 3. If the WCM is electronically locked up, the StarSCAN(R) will display the WCM as being "off bus". 4. If the no crank / no start condition is present, and the WCM is "off bus", then reset the WCM by temporarily removing the IOD fuse (with the key out of the ignition switch), wait for 10 seconds and then reinstall the IOD fuse. 5. With the IOD fuse reset having been performed, verify that the vehicle will now crank, start, and run. 6. If the condition is temporarily corrected by performing the above steps, and if the part number of the WCM is earlier than the part number of the WCM listed in the part reference table in the Service Bulletin Parts Required Section below, then perform the Repair Procedure. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 5963 PARTS REQUIRED: NOTE: The part numbers listed in the following part reference table are to be used as A GUIDE to help determine if the WCM, that is currently in the vehicle, may require replacement. If it is determined that the WCM requires replacement, then ALWAYS REFER TO THE PARTS MANUAL to determine the correct WCM for the specific vehicle in question. In some earlier model years, the WCM may rule (supersede) to one of the part numbers listed in the table. ALWAYS REFER TO THE PARTS MANUAL (not the part reference table) to determine the correct part number ruling (supercedence / substitution). MAKE CERTAIN THAT THE CORRECT WCM IS ORDERED THE FIRST TIME FOR THE SPECIFIC VEHICLE IN QUESTION. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 5964 REPAIR PROCEDURE: NOTE: If the vehicle (a JS model vehicle in certain International markets) is equipped with an Electric Steering Column Lock (ELV), then the WCM and the ELV must be replaced. Replace the WCM and then the ELV. Next program the WCM and at least one (1) ignition key BEFORE programming the ELV. IMPORTANT: Not following this repair process correctly will cause the new ELV to fail. NOTE: Insert the ignition key into the ignition lock cylinder. This will move the shaft lock module locking bolt to the unlocked position. LEAVE the key in the lock cylinder while the shaft lock module is being removed. 1. If vehicle is equipped with a Steering Shaft Lock Module (JS - Avenger I Stratus - some International Markets), then the Shaft Lock Module will require replacement. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Security Information > Module, Shaft Lock > Removal and Installation. NOTE: The shaft lock module cannot be removed from the steering column while the locking bolt is in the locked position without irreversibly damaging the column. Before attempting service, the ignition key must have been inserted into the ignition lock cylinder. Then rotate the steering wheel from side to side. If the steering wheel can be rotated, the locking bolt is in the unlocked position. Leave the key in the ignition lock cylinder until shaft lock module removal has been completed. If the steering wheel cannot be rotated, test and repair the wiring circuits between the module and the ignition switch as required. If no problem is found in these circuits, the module has failed with the locking bolt in the locked position and both the module and the steering column must be replaced with new units. 2. Replace the WCM/SKREEM. Refer to TechCONNECT for detailed service information. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Service Information > Module, Sentry Key Remote Entry > Removal and Installation. NOTE: Obtain the vehicle PIN number prior to programming WCM/SKREEM or ELV. NOTE: If during the following steps the PIN number is properly entered but is rejected, then reenter the PIN number again until it is accepted. 3. After both the WCM/SKREEM and the ELV (if equipped) have been replaced, Program the WCM/SKREEM as follows: a. Turn the ignition key to the ON position, (Engine Off) b. Connect the scan tool (StarSCAN(R)) to the data link connector and turn the ignition to the RUN position, (engine off). c. Select "ECU View." d. Scroll down and select "WCM" in the list of modules. e. Select "Misc. Functions." f. Scroll to "WCM Replaced." g. Press "Start". h. Press "Next". i. Select "Show Keyboard". j. Enter the vehicle PIN number. k. Select "Next". l. Verify PIN is correct. m. Select "Next". n. Follow on-screen prompts to complete WCM function programing for Tire Pressure Monitoring (TPM) and so on. 0. Turn the ignition key to the OFF position. Wait 30 seconds. p. Turn the ignition key to the ON position, (Engine Off) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 5965 q. Select "ECU View". r. Scroll down and select "WCM" in the list of modules. s. Select "Misc. Functions." t. Select "Program Ign. Keys" and follow on-screen prompts. u. Select "Complete". v. Verify ignition key will start vehicle and the Remote Keyless Entry (RKE) functions operate. CAUTION: If the vehicle is equipped with a Shaft Lock Module (used in some International Markets on JS model vehicles), then at least one (1 ignition key must have been programmed to the new WCM BEFORE the new Shaft Lock Module is "married" to the new WCM. 4. Is the vehicle equipped with Steering Shaft Lock Module (ELV)? a. Yes >> Proceed to Step # 5. b. No >>Repair is complete. 5. Program the ELV as follows; a. Select "ECU View". b. Scroll down and select "WCM" in the list of modules. c. Select "Misc. Functions". d. Scroll to "ELV Replaced." e. Press "Start". f. When complete, verify steering shaft lock mechanism is operating. Remove and insert key from the ignition lock cylinder and listen for solenoid "click at lower end of column. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 5966 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Distribution Module: > G42 > Jan > 08 > Campaign - TIPM Software Update for Antitheft System Technical Service Bulletin # G42 Date: 080101 Campaign - TIPM Software Update for Antitheft System January 2008 Distributor/Dealer Service Instructions for: Customer Satisfaction Notice G42 TIPM Re-Configure, Anti-Theft System Models 2007 2008 (JS/PM/MK) Sebring, Avenger, Caliber, Compass and Patriot vehicles (International Markets Only) NOTE: This customer satisfaction notice applies only to the above vehicles built at the Sterling Heights Assembly Plant through July 25, 2007 (MDH 0725XX) and the Belvidere Assembly Plant through July 23, 2007 (MDH 0723XX). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this customer satisfaction notice. IMPORTANT: Some of the involved vehicles may be in distributor/dealer used vehicle inventory. Distributors/Dealers should complete this recall service on these vehicles before retail delivery. Distributors/Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Totally Integrated Power Module (TIPM) vehicles may be configured incorrectly preventing the Anti-Theft Security System from operating properly. Repair The Totally Integrated Power Module (TIPM) must be Re-Configured. Special Tools These existing special tools are required to perform this repair. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Distribution Module: > G42 > Jan > 08 > Campaign - TIPM Software Update for Antitheft System > Page 5972 Use the labor operation number and time allowance shown. Distributor/ Dealer Notification and Vehicle List Regional offices will receive an electronic list of involved vehicles. The Vehicle List is arranged by Distributor/Dealer code and in Vehicle Identification Number (VIN) sequence. The lists are for Distributor/Dealer reference in arranging for service of involved vehicles. Owner Notification and Service Scheduling All involved vehicle owners should be notified of the service requirement by their Distributor/Dealer. Owners are requested to schedule appointments for this service. A sample copy of the owner notification letter is included. Vehicle Lists, Global Recall System, VIP and Distributor/Dealer Follow up All involved vehicles have been entered into the Global Recall System (GRS) and Vehicle Information Plus (VIP) for Distributor/Dealer inquiry as needed. GRS provides involved Distributors/Dealers with an updated VIN list of their incomplete vehicles. Completed vehicles are removed from GRS within several days of repair claim submission. Distributors/Dealers must perform this repair on all unsold vehicles before retail delivery. Distributors/Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Additional Information If you have any questions or need assistance in completing this action, please contact your International Service and Parts Manager. Global Service & Parts - International Chrysler LLC Service Procedure NOTE: Use StarSCAN(R) to perform this Customer Satisfaction Notice. This procedure must be performed using software release 8.02 or higher. Re-Configure the TIPM using StarSCAN(R) 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN(R) Ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN® vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN(R). 5. Re-Configure the TIPM as Follows: a. With the StarSCAN(R) on the "Home" screen, select "ECU View". b. Select "TIPMCGW Central Gateway" in the list of modules. c. Select "Misc Functions". Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Distribution Module: > G42 > Jan > 08 > Campaign - TIPM Software Update for Antitheft System > Page 5973 d. Select "Restore Vehicle Configuration". e. Press "Start". f. Follow the prompts listed on the StarSCAN(R). g. When prompted, Enter the full 17 digit VIN found on the VIN plate. NOTE: Assure the correct VIN is input into the StarSCAN(R). h. Select "Next". NOTE: The StarSCAN(R) must be connected to the dealer network drop. i. Follow the prompts listed on the StarSCAN(R). 6. Check and clear any Diagnostic Trouble Codes (DTC's) that may have been set. 7. Turn the ignition key to the "OFF" position and remove the StarSCAN(R) unit, StarSCAN(R) cable, and battery charger from the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead Power Distribution Module: Locations Module-Electronic Overhead Component ID: 148 Component : MODULE-ELECTRONIC OVERHEAD Connector: Name : MODULE-ELECTRONIC OVERHEAD C1 Color : BLACK # of pins : 3 A READING/RAIL LAMPS DRIVER M27 20YL/LB B GROUND Z936 20BK/LB C COURTESY LAMPS DRIVER M24 20YL/WT Component Location - 43 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5976 Connector: Name : MODULE-ELECTRONIC OVERHEAD C2 Color : BLACK # of pins : 4 A SUNROOF VENT SWITCH SENSE Q4 20OR/YL B SUNROOF SWITCH SUPPLY Q6 20OR/LG C SUNROOF OPEN SWITCH SENSE Q3 20OR/TN D SUNROOF CLOSE SWITCH SENSE Q5 20OR/LB Component Location - 43 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5977 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5978 Power Distribution Module: Locations Module-Totally Integrated Power Component ID: 163 Component : MODULE-TOTALLY INTEGRATED POWER Connector: Name : MODULE-TOTALLY INTEGRATED POWER C1 Color : BLACK # of pins : 13 Pin Description Circuit 1 REAR WASHER PUMP MOTOR CONTROL W20 20BR/YL 2 FRONT WASHER PUMP MOTOR CONTROL W10 20BR/TN 3 IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4-5-6 CABIN HEATER RELAY 2 CONTROL K232 20BR/LB 7 CABIN HEATER RELAY 1 CONTROL K132 20DB/LB 8-9-10 - 11 - 12 BRAKE FLUID LEVEL SWITCH SENSE B20 20DG/RD 13 GROUND Z924 20BK/LB Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5979 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5980 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C10 Color : LT. GRAY # of pins : 8 Pin Description Circuit 1-2-3 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 4-5 FUSED MAIN RELAY OUTPUT F343 18DB/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5981 6 FUSED MAIN RELAY OUTPUT F344 18DB/LB 7-8 STARTER CONTROL OUTPUT T750 16YL/GY Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5982 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C11 Color : GREEN # of pins : 22 Pin Description Circuit 1 FUSED MAIN RELAY OUTPUT F342 14BR/DG 2-3-4 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 5 FRONT FOG LAMP CONTROL OUTPUT L89 20WT/YL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5983 6 FRONT FOG LAMP CONTROL OUTPUT L90 20WT/OR 7 LOW/HIGH RAD FAN RELAY CONTROL N201 20DB/LG 8 HORN CONTROL OUTPUT X22 20GY/LB 9 HORN CONTROL OUTPUT X21 20GY/YL 10 FRONT WIPER HIGH SPEED CONTROL OUTPUT W4 16BR/LB 11 FUSED B(+) A935 20RD/LB 12 FRONT WIPER LOW SPEED CONTROL OUTPUT W3 16BR/WT 13 FUSED IGNITION SWITCH OUTPUT (RUN) F936 20PK/YL 14 FUSED B(+) (VALVE) A922 14RD/BK 15 - 16 - - 17 FUSED B(+) (PUMP) A921 12RD/DB 18 - 19 FUSED B(+) A931 20RD/WT 20 - 21 GROUND Z971 16BK 22 RAD FAN RELAY CONTROL N112 20DB/OR Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5984 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C2 Color : LT. GRAY # of pins : 14 Pin Description Circuit 1 IGNITION SWITCH OUTPUT (UNLOCK-RUN-START) F901 20PK/RD 2 STARTER CONTROL T752 20DG/OR 3-4 FUEL PUMP CONTROL K31 20DB/BK 4 FUEL PUMP CONTROL K31 20BR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5985 5 FRONT WIPER PARK SWITCH SENSE W7 20BR/DB 6 GROUND Z924 20BK/LB 7 CAN C BUS (+) D265 20WT/BK 8-9-10 IGNITION SWITCH OUTPUT (UNLOCK-RUN-START) F901 20PK/RD 11 HOOD AJAR SWITCH SENSE G70 20VT/LB 12 - 13 GROUND Z925 20BK/YL 14 CAN C BUS (-) D264 20DB/WT Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5986 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C3 Color : BROWN # of pins : 16 Pin Description Circuit 1 CAN C BUS (+) D65 20WT/BK 2 DIAGNOSTIC CAN C (+) D72 20WT/TN 3 CAN B BUS (+) D55 20WT/OR 4 LEFT REAR TURN SIGNAL L63 20DG/RD 5-- Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5987 6 RIGHT REAR TURN SIGNAL L62 20WT/YL 7 STOP LAMP SWITCH OUTPUT L53 20DG/WT 8 PARK LAMP CONTROL OUTPUT L217 20WT/VT 9 CAN C BUS (-) D64 20WT/LB 10 DIAGNOSTIC CAN C (-) D71 20WT/DB 11 CAN B BUS (-) D54 20WT/PK 12 IGNITION SWITCH OUTPUT (START) F961 20PK/LB 13 STOP LAMP CONTROL OUTPUT L55 20WT/OR 14 - 15 RIGHT REAR WHEEL SPEED SENSOR SIGNAL B1 20YL/DB 16 RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY B2 20DG/TN Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5988 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C4 Color : BLACK # of pins : 10 Pin Description Circuit 1 LEFT TURN SIGNAL L61 20WT/RD 2 RIGHT TURN SIGNAL L60 20WT/TN 3 RIGHT HIGH BEAM OUTPUT L34 20WT/GY 4 LEFT LOW BEAM OUTPUT L43 20WT/DB 5-- Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5989 6-7-8 AAT SIGNAL G31 20VT/LG 9 AAT RETURN G931 20VT/DB 10 - Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5990 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C5 Color : BLUE # of pins : 14 Pin Description Circuit 1 HEADLAMP SWITCH OUTPUT L70 20WT/GY 2 RIGHT TURN SIGNAL (OUT) L160 20WT/TN 3 RIGHT LOW BEAM OUTPUT L44 20VT/RD 4 LEFT HIGH BEAM OUTPUT L33 20WT/PK 5 LEFT TURN SIGNAL (OUT) L161 20WT/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5991 6 HEADLAMP SWITCH OUTPUT L7 20WT/VT 6 HEADLAMP SWITCH OUTPUT L7 20WT/YL 7 A/C PRESSURE SENSOR SUPPLY C818 20LB/TN 8 BACKUP LAMP SWITCH SIGNAL T22 20YL/VT 9 HEADLAMP LEVEL SENSOR SIGNAL L131 20WT/LG 10 HEADLAMP LEVEL SENSOR SIGNAL L132 20LG/WT 11 - 12 A/C PRESSURE SENSOR SIGNAL C18 20LB/BR 13 A/C PRESSURE SENSOR GROUND C918 20BK/LB 14 IGNITION SWITCH OUTPUT (START) F962 20PK/BK Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5992 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C6 Color : LT. GRAY # of pins : 13 Pin Description Circuit 1-2-3-4-5 REAR WIPER MOTOR CONTROL W13 20BR/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5993 6-7-8-9-10 - 11 - 12 REAR FOG LAMP CONTROL OUTPUT L239 20WT/DG 13 - Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5994 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C7 Color : LT. GRAY # of pins : 22 Pin Description Circuit 1-2 FUSED B(+) A923 18RD/WT 2 FUSED B(+) A923 20RD/WT 3 FUSED B(+) A924 20DG/WT 4 FUSED B(+) A952 20RD/OR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5995 5 FUSED IGNITION SWITCH OUTPUT (RUN-START) F200 20PK/LB 6 FUSED B(+) A100 18RD/VT 7 FUSED IGNITION SWITCH OUTPUT (RUN) F100 20DG/YL 8-9 FUSED B(+) A933 20RD/LG 10 - 11 FUEL PUMP CONTROL OUTPUT N1 16DB/OR 12 - 13 FUSED B(+) (I.O.D.) A417 20RD/DG 14 - 15 FUSED B(+) (I.O.D.) A418 20RD/BK 16 FUSED B(+) (I.O.D.) A412 20RD/DB 17 FUSED B(+) A16 12RD/BR 18 DOOR LOCK POWER-FUSED B(+) A932 18RD/BR 19 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F996 20PK/YL 20 - 21 IGNITION SWITCH OUTPUT (RUN-ACC) F981 14PK/BR 22 FUSED B(+) A999 18RD/PK Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5996 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C8 Color : BLACK # of pins : 22 Pin Description Circuit 1 BLOWER MOTOR CONTROL C7 12DB/PK 2 FUSED B(+) A927 16RD/GY 3 FUSED B(+) (I.O.D.) A415 20RD/TN 4 FUSED B(+) (I.O.D.) A414 20RD/DG 5 FUSED B(+) (I.O.D.) A416 18RD Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5997 6 FUSED B(+) (I.O.D.) A420 18WT/RD 7 FUSED B(+) A14 12RD/YL 8 FUSED IGNITION SWITCH OUTPUT (RUN) F937 18PK/YL 9 FUSED REAR WINDOW DEFOGGER CONTROL OUTPUT C16 20DB/GY 10 - 11 BACKUP LAMP SWITCH OUTPUT L1 20WT/LG 12 FUSED IGNITION SWITCH OUTPUT (RUN) F929 20PK/RD 13 FUSED B(+) (I.O.D.) A411 20RD/LG 14 FUSED B(+) (I.O.D.) A419 18RD/DG 15 - 16 - - 17 REAR WINDOW DEFOGGER CONTROL OUTPUT C515 12LB/OR 18 FUSED B(+) (I.O.D.) A413 18RD/LB 19 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 20 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F985 18PK/YL 21 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F986 20PK/BK 22 MAIN RELAY OUTPUT K542 12BR/WT Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5998 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C9 Color : # of pins : 1 Pin Description Circuit 1 B(+) A0 6RD Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 5999 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6000 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6001 Power Distribution Module: Locations Module-Inverter Component ID: 157 Component : MODULE-INVERTER Connector: Name : MODULE-INVERTER Color : # of pins : 9 Qualifier : (EXCEPT EXPORT) Pin Description Circuit 1 FUSED B(+) A999 16RD/PK 2-3 110 VOLT AC LINE 1 P801 18LG/PK 4 GROUND Z940 14BK/LG 5 INVERTER ENABLE SWITCH SIGNAL P805 18LG/DB 6-- 7-8 110 VOLT AC COMMON P809 18LG/LB 9-Component Location - 24 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6002 Component Location - 26 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6003 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead Power Distribution Module: Diagrams Module-Electronic Overhead Component ID: 148 Component : MODULE-ELECTRONIC OVERHEAD Connector: Name : MODULE-ELECTRONIC OVERHEAD C1 Color : BLACK # of pins : 3 A READING/RAIL LAMPS DRIVER M27 20YL/LB B GROUND Z936 20BK/LB C COURTESY LAMPS DRIVER M24 20YL/WT Component Location - 43 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6006 Connector: Name : MODULE-ELECTRONIC OVERHEAD C2 Color : BLACK # of pins : 4 A SUNROOF VENT SWITCH SENSE Q4 20OR/YL B SUNROOF SWITCH SUPPLY Q6 20OR/LG C SUNROOF OPEN SWITCH SENSE Q3 20OR/TN D SUNROOF CLOSE SWITCH SENSE Q5 20OR/LB Component Location - 43 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6007 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6008 Power Distribution Module: Diagrams Module-Totally Integrated Power Component ID: 163 Component : MODULE-TOTALLY INTEGRATED POWER Connector: Name : MODULE-TOTALLY INTEGRATED POWER C1 Color : BLACK # of pins : 13 Pin Description Circuit 1 REAR WASHER PUMP MOTOR CONTROL W20 20BR/YL 2 FRONT WASHER PUMP MOTOR CONTROL W10 20BR/TN 3 IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4-5-6 CABIN HEATER RELAY 2 CONTROL K232 20BR/LB 7 CABIN HEATER RELAY 1 CONTROL K132 20DB/LB 8-9-10 - 11 - 12 BRAKE FLUID LEVEL SWITCH SENSE B20 20DG/RD 13 GROUND Z924 20BK/LB Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6009 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6010 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C10 Color : LT. GRAY # of pins : 8 Pin Description Circuit 1-2-3 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 4-5 FUSED MAIN RELAY OUTPUT F343 18DB/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6011 6 FUSED MAIN RELAY OUTPUT F344 18DB/LB 7-8 STARTER CONTROL OUTPUT T750 16YL/GY Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6012 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C11 Color : GREEN # of pins : 22 Pin Description Circuit 1 FUSED MAIN RELAY OUTPUT F342 14BR/DG 2-3-4 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 5 FRONT FOG LAMP CONTROL OUTPUT L89 20WT/YL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6013 6 FRONT FOG LAMP CONTROL OUTPUT L90 20WT/OR 7 LOW/HIGH RAD FAN RELAY CONTROL N201 20DB/LG 8 HORN CONTROL OUTPUT X22 20GY/LB 9 HORN CONTROL OUTPUT X21 20GY/YL 10 FRONT WIPER HIGH SPEED CONTROL OUTPUT W4 16BR/LB 11 FUSED B(+) A935 20RD/LB 12 FRONT WIPER LOW SPEED CONTROL OUTPUT W3 16BR/WT 13 FUSED IGNITION SWITCH OUTPUT (RUN) F936 20PK/YL 14 FUSED B(+) (VALVE) A922 14RD/BK 15 - 16 - - 17 FUSED B(+) (PUMP) A921 12RD/DB 18 - 19 FUSED B(+) A931 20RD/WT 20 - 21 GROUND Z971 16BK 22 RAD FAN RELAY CONTROL N112 20DB/OR Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6014 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C2 Color : LT. GRAY # of pins : 14 Pin Description Circuit 1 IGNITION SWITCH OUTPUT (UNLOCK-RUN-START) F901 20PK/RD 2 STARTER CONTROL T752 20DG/OR 3-4 FUEL PUMP CONTROL K31 20DB/BK 4 FUEL PUMP CONTROL K31 20BR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6015 5 FRONT WIPER PARK SWITCH SENSE W7 20BR/DB 6 GROUND Z924 20BK/LB 7 CAN C BUS (+) D265 20WT/BK 8-9-10 IGNITION SWITCH OUTPUT (UNLOCK-RUN-START) F901 20PK/RD 11 HOOD AJAR SWITCH SENSE G70 20VT/LB 12 - 13 GROUND Z925 20BK/YL 14 CAN C BUS (-) D264 20DB/WT Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6016 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C3 Color : BROWN # of pins : 16 Pin Description Circuit 1 CAN C BUS (+) D65 20WT/BK 2 DIAGNOSTIC CAN C (+) D72 20WT/TN 3 CAN B BUS (+) D55 20WT/OR 4 LEFT REAR TURN SIGNAL L63 20DG/RD 5-- Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6017 6 RIGHT REAR TURN SIGNAL L62 20WT/YL 7 STOP LAMP SWITCH OUTPUT L53 20DG/WT 8 PARK LAMP CONTROL OUTPUT L217 20WT/VT 9 CAN C BUS (-) D64 20WT/LB 10 DIAGNOSTIC CAN C (-) D71 20WT/DB 11 CAN B BUS (-) D54 20WT/PK 12 IGNITION SWITCH OUTPUT (START) F961 20PK/LB 13 STOP LAMP CONTROL OUTPUT L55 20WT/OR 14 - 15 RIGHT REAR WHEEL SPEED SENSOR SIGNAL B1 20YL/DB 16 RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY B2 20DG/TN Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6018 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C4 Color : BLACK # of pins : 10 Pin Description Circuit 1 LEFT TURN SIGNAL L61 20WT/RD 2 RIGHT TURN SIGNAL L60 20WT/TN 3 RIGHT HIGH BEAM OUTPUT L34 20WT/GY 4 LEFT LOW BEAM OUTPUT L43 20WT/DB 5-- Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6019 6-7-8 AAT SIGNAL G31 20VT/LG 9 AAT RETURN G931 20VT/DB 10 - Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6020 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C5 Color : BLUE # of pins : 14 Pin Description Circuit 1 HEADLAMP SWITCH OUTPUT L70 20WT/GY 2 RIGHT TURN SIGNAL (OUT) L160 20WT/TN 3 RIGHT LOW BEAM OUTPUT L44 20VT/RD 4 LEFT HIGH BEAM OUTPUT L33 20WT/PK 5 LEFT TURN SIGNAL (OUT) L161 20WT/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6021 6 HEADLAMP SWITCH OUTPUT L7 20WT/VT 6 HEADLAMP SWITCH OUTPUT L7 20WT/YL 7 A/C PRESSURE SENSOR SUPPLY C818 20LB/TN 8 BACKUP LAMP SWITCH SIGNAL T22 20YL/VT 9 HEADLAMP LEVEL SENSOR SIGNAL L131 20WT/LG 10 HEADLAMP LEVEL SENSOR SIGNAL L132 20LG/WT 11 - 12 A/C PRESSURE SENSOR SIGNAL C18 20LB/BR 13 A/C PRESSURE SENSOR GROUND C918 20BK/LB 14 IGNITION SWITCH OUTPUT (START) F962 20PK/BK Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6022 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C6 Color : LT. GRAY # of pins : 13 Pin Description Circuit 1-2-3-4-5 REAR WIPER MOTOR CONTROL W13 20BR/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6023 6-7-8-9-10 - 11 - 12 REAR FOG LAMP CONTROL OUTPUT L239 20WT/DG 13 - Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6024 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C7 Color : LT. GRAY # of pins : 22 Pin Description Circuit 1-2 FUSED B(+) A923 18RD/WT 2 FUSED B(+) A923 20RD/WT 3 FUSED B(+) A924 20DG/WT 4 FUSED B(+) A952 20RD/OR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6025 5 FUSED IGNITION SWITCH OUTPUT (RUN-START) F200 20PK/LB 6 FUSED B(+) A100 18RD/VT 7 FUSED IGNITION SWITCH OUTPUT (RUN) F100 20DG/YL 8-9 FUSED B(+) A933 20RD/LG 10 - 11 FUEL PUMP CONTROL OUTPUT N1 16DB/OR 12 - 13 FUSED B(+) (I.O.D.) A417 20RD/DG 14 - 15 FUSED B(+) (I.O.D.) A418 20RD/BK 16 FUSED B(+) (I.O.D.) A412 20RD/DB 17 FUSED B(+) A16 12RD/BR 18 DOOR LOCK POWER-FUSED B(+) A932 18RD/BR 19 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F996 20PK/YL 20 - 21 IGNITION SWITCH OUTPUT (RUN-ACC) F981 14PK/BR 22 FUSED B(+) A999 18RD/PK Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6026 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C8 Color : BLACK # of pins : 22 Pin Description Circuit 1 BLOWER MOTOR CONTROL C7 12DB/PK 2 FUSED B(+) A927 16RD/GY 3 FUSED B(+) (I.O.D.) A415 20RD/TN 4 FUSED B(+) (I.O.D.) A414 20RD/DG 5 FUSED B(+) (I.O.D.) A416 18RD Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6027 6 FUSED B(+) (I.O.D.) A420 18WT/RD 7 FUSED B(+) A14 12RD/YL 8 FUSED IGNITION SWITCH OUTPUT (RUN) F937 18PK/YL 9 FUSED REAR WINDOW DEFOGGER CONTROL OUTPUT C16 20DB/GY 10 - 11 BACKUP LAMP SWITCH OUTPUT L1 20WT/LG 12 FUSED IGNITION SWITCH OUTPUT (RUN) F929 20PK/RD 13 FUSED B(+) (I.O.D.) A411 20RD/LG 14 FUSED B(+) (I.O.D.) A419 18RD/DG 15 - 16 - - 17 REAR WINDOW DEFOGGER CONTROL OUTPUT C515 12LB/OR 18 FUSED B(+) (I.O.D.) A413 18RD/LB 19 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 20 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F985 18PK/YL 21 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F986 20PK/BK 22 MAIN RELAY OUTPUT K542 12BR/WT Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6028 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C9 Color : # of pins : 1 Pin Description Circuit 1 B(+) A0 6RD Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6029 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6030 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6031 Power Distribution Module: Diagrams Module-Inverter Component ID: 157 Component : MODULE-INVERTER Connector: Name : MODULE-INVERTER Color : # of pins : 9 Qualifier : (EXCEPT EXPORT) Pin Description Circuit 1 FUSED B(+) A999 16RD/PK 2-3 110 VOLT AC LINE 1 P801 18LG/PK 4 GROUND Z940 14BK/LG 5 INVERTER ENABLE SWITCH SIGNAL P805 18LG/DB 6-- 7-8 110 VOLT AC COMMON P809 18LG/LB 9-Component Location - 24 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6032 Component Location - 26 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6033 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Totally Integrated Power Module Power Distribution Module: Description and Operation Totally Integrated Power Module Description DESCRIPTION All of the electrical current distributed throughout this vehicle is directed through the standard equipment Totally Integrated Power Module (TIPM) (1). The molded plastic TIPM housing is located in the left front corner of the engine compartment, just behind the air cleaner housing and the battery. The TIPM housing has a molded plastic cover. The TIPM cover is easily removed for service access and has a convenient fuse and relay layout label affixed to the inside surface of the cover to ensure proper component identification. The TIPM housing is secured to the left inner fender well an indexing pin and one screw. All of the TIPM outputs are through the integral engine compartment wire harness. Operation OPERATION All of the current from the generator cable connection goes to the battery through a 10 gauge fusible link that is secured with a nut to the positive battery terminal at the starter. Internal connection of all the Totally Integrated Power Module (TIPM) circuits is accomplished by an intricate network of hard wiring and bus bars. Refer to Wiring Diagrams for complete circuit diagrams. The fusible link, fuses and relays are available for service replacement. The TIPM unit cannot be repaired and is only serviced as a unit with the engine compartment wire harness. If the TIPM is inoperative or damaged, the engine compartment wire harness assembly must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Totally Integrated Power Module > Page 6036 Power Distribution Module: Description and Operation Module-Inverter Description DESCRIPTION The inverter module is located in the instrument panel. The A/C outlet is mounted in the center console. The inverter module provides A/C power for user accessories. The inverter converts the 12 Volt DC from the battery system to a 110 Volt AC output. Operation OPERATION The AC power outlet receives 12 volts from the Totally Integrated Power Module (TIPM) and passes it as an enable signal to the inverter module. The inverter module also receives 12 volts via the TIPM and inverts this to a 110 volt AC output. The enable signal received from the power outlet enables the inverter to convert the received voltage and pass it to the power outlet to power external devices. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Page 6037 Power Distribution Module: Testing and Inspection Inverter Module For complete circuit diagrams, refer to the appropriate wiring information. WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Totally Integrated Power Module Power Distribution Module: Service and Repair Totally Integrated Power Module Removal REMOVAL The TIPM (TIPM) is serviced as a unit with the engine compartment wire harness. If any internal circuit of the TIPM or the TIPM housing is faulty or damaged, the entire TIPM and engine compartment wire harness unit must be replaced. Refer to Wiring Diagrams for the locations of the affected connectors. 1. Open hood. 2. Disconnect and isolate the battery negative cable. 3. Disconnect each of the engine compartment wire harness connectors. 4. Remove the fasteners that secure each of the engine compartment wire harness ground eyelets to the vehicle body and chassis components. 5. Disengage each of the retainers that secure the engine compartment wire harness to the vehicle body and chassis components. 6. Disengage and remove the TIPM housing from its mounting bracket. 7. Remove the TIPM and the engine compartment wire harness from the engine compartment as a unit. Installation INSTALLATION The Totally Integrated Power Module (TIPM) is serviced as a unit with the engine compartment wire harness. If any internal circuit of the TIPM or the TIPM housing is faulty or damaged, the entire TIPM and engine compartment wire harness unit must be replaced. NOTE: If the Totally Integrated Power Module (TIPM) is being replaced with a new unit, be certain to transfer each of the fuses and relays from the old TIPM to the proper cavities of the new TIPM. Refer to Wiring Diagrams for the proper TIPM cavity assignments. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Totally Integrated Power Module > Page 6040 1. Position the TIPM in the engine compartment. 2. Align the TIPM on its mounting bracket and install. 3. Route the engine compartment wire harness from the TIPM through the engine compartment, engaging each of the harness retainers to the mounting provisions in the vehicle body and chassis components. Refer to Wiring Diagrams for the harness routing and retainer locations. 4. Install and tighten the fasteners that secure each of the engine compartment wire harness ground eyelets to the vehicle body and chassis components. Refer to Wiring Diagrams for the ground eyelet locations. 5. Reconnect each of the engine compartment wire harness connectors. Refer to Wiring Diagrams for the locations of the affected connectors. 6. Torque nut retaining positive battery cable at TIPM to 96 - 141 Nm (85 - 130 in. lbs.). 7. Reconnect the battery negative cable. 8. Close hood. 9. Verify vehicle and system operation. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Totally Integrated Power Module > Page 6041 Power Distribution Module: Service and Repair Module-Inverter Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. 1. Disconnect and isolate the negative battery cable. 2. Remove the shift bezel. 3. Remove the center bezel from the instrument panel. 4. Remove the fasteners from the mounting brackets of the inverter module. 5. Disconnect the electrical connectors and remove the inverter module. Installation INSTALLATION 1. Connect the electrical connectors to the inverter module. 2. Install the fasteners to the mounting brackets. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Totally Integrated Power Module > Page 6042 3. Install the center bezel to the instrument panel. 4. Install the shift bezel. 5. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Removal Power Distribution Relay: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove cover from Totally Integrated Power module (TIPM). 3. Using special tool C-4817 (1), grip the relay (2) by the sides and pull upward with an even effort. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Removal > Page 6047 Power Distribution Relay: Service and Repair Installation INSTALLATION 1. Align relay (2) with Totally Integrated Power Module (TIPM) and press into position. 2. Install cover to TIPM. 3. Connect battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6051 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6052 Relay Box: Application and ID Fuse/Relay Block Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6056 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6057 Relay Box: Application and ID Fuse/Relay Block Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Power Interrupt Connector/Switch > Component Information > Description and Operation > Description Power Interrupt Connector/Switch: Description and Operation Description DESCRIPTION All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is disconnected within the Totally Integrated Power Module (TIPM) when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the TIPM as part of the preparation procedures performed just prior to new vehicle delivery. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Power Interrupt Connector/Switch > Component Information > Description and Operation > Description > Page 6063 Power Interrupt Connector/Switch: Description and Operation Operation OPERATION The term ignition-off draw identifies a normal condition where power is being drained from the battery with the ignition switch in the Off position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the Off position, including the clock. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is disconnected from Totally Integrated Power Module (TIPM) fuse cavities 7 and 8 in a preset fuse holder. when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse serves no useful purpose to the dealer technician in the service or diagnosis of any vehicle system or condition, other than the same purpose as that of any other standard circuit protection device. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Power Interrupt Connector/Switch > Component Information > Service and Repair > Removal Power Interrupt Connector/Switch: Service and Repair Removal REMOVAL NOTE: When removing or installing the IOD fuse, it is important that the ignition switch be in the Off position. Failure to place the ignition switch in the Off position can cause the radio display to become scrambled when the IOD fuse is installed. Removing and installing the IOD fuse again with the ignition switch in the Off position will usually correct the scrambled radio display condition. 1. Turn the ignition switch to the Off position. 2. Remove the cover from the Totally Integrated Power Module (TIPM). 3. Remove fuse 7/8 from the TIPM. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Power Interrupt Connector/Switch > Component Information > Service and Repair > Removal > Page 6066 Power Interrupt Connector/Switch: Service and Repair Installation INSTALLATION CAUTION: It is extremely important that the Ignition Off Draw (IOD) fuses are fully seated into the Totally Integrated Power Module (TIPM) fuse cavities. Failure to install the fuses correctly could result in erratic electrical systems behavior. 1. Remove TIPM cover. 2. Insert fuse 7/8 into the TIPM. Push fuses down until they are fully seated in the TIPM cavities. 3. Install the cover to the TIPM. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > Power Outlet-AC Auxiliary Power Outlet: Locations Power Outlet-AC Component ID: 175 Component : POWER OUTLET-AC Connector: Name : POWER OUTLET-AC Color : ORANGE # of pins : 6 Qualifier : (EXCEPT EXPORT) Pin Description Circuit 1 INVERTER ENABLE SWITCH SIGNAL P805 18LG/LB 2-3 110 VOLT AC LINE 1 P801 18LG 4 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F996 18PK/YL 5-6 110 VOLT AC COMMON P809 18LG/TN Component Location - 40 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > Power Outlet-AC > Page 6072 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > Power Outlet-AC > Page 6073 Auxiliary Power Outlet: Locations Power Outlet-Instrument Panel Component ID: 176 Component : POWER OUTLET-INSTRUMENT PANEL Connector: Name : POWER OUTLET-INSTRUMENT PANEL Color : GRAY # of pins : 3 Pin Description Circuit 1 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F986 20PK/BK 2-3 GROUND Z940 20BK/LG Component Location - 35 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > Power Outlet-AC > Page 6074 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: Provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6077 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6078 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6079 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6080 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6081 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6082 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6083 5. Release the Secondary Terminal Lock, if required (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6084 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6085 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6086 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6087 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6088 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6089 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6090 Auxiliary Power Outlet: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6091 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6092 STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6093 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6094 Auxiliary Power Outlet: Connector Views Power Outlet-AC Component ID: 175 Component : POWER OUTLET-AC Connector: Name : POWER OUTLET-AC Color : ORANGE # of pins : 6 Qualifier : (EXCEPT EXPORT) Pin Description Circuit 1 INVERTER ENABLE SWITCH SIGNAL P805 18LG/LB 2-3 110 VOLT AC LINE 1 P801 18LG 4 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F996 18PK/YL 5-- 6 110 VOLT AC COMMON P809 18LG/TN Component Location - 40 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6095 Power Outlet-Instrument Panel Component ID: 176 Component : POWER OUTLET-INSTRUMENT PANEL Connector: Name : POWER OUTLET-INSTRUMENT PANEL Color : GRAY # of pins : 3 Pin Description Circuit Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6096 1 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F986 20PK/BK 2-3 GROUND Z940 20BK/LG Component Location - 35 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6097 Auxiliary Power Outlet: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-41-02 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6098 8w-41-03 Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description and Operation > Description Auxiliary Power Outlet: Description and Operation Description DESCRIPTION INSTRUMENT PANEL MOUNTED An instrument panel mounted cigar lighter/power outlet receptacle is optional equipment on this model. On models equipped with the optional Smoker's Package, the cigar lighter knob and heating element are included. On models without the Smoker's Package, the cigar lighter receptacle is equipped with a snap fit plastic cap and is treated as an auxiliary power outlet. The cigar lighter receptacle is installed in the instrument panel accessory switch bezel, which is located near the bottom of the instrument panel center stack area, below the radio. The cigar lighter base is secured by a snap fit within the center lower bezel. This power outlet has a constant 12 volt battery feed. The cigar lighter receptacle is serviced with the accessory switch bezel and if defective, the entire switch bezel must be replaced. The plastic cap and the knob and heating element unit are available for service replacement. These components cannot be repaired and, if faulty or damaged, they must be replaced. FRONT CONSOLE AND REAR CARGO MOUNTED A front console mounted power outlet is standard equipment and a rear cargo area power outlet is optional equipment on this model. The front console mounted power outlet is mounted near the front of the console just in front of the cup holders. This outlet can be used as a cigar lighter or power outlet, but only has 12 volt battery voltage when the ignition is in the ON or ACC positions. The rear power outlet is installed in the right rear quarter trim panel, near the spare tire jack (2). The power outlet base and mount are secured by a snap fit within the quarter trim panel. A plastic protective cap snaps into the power outlet base when the power outlet is not being used, and hangs from the power outlet base mount by an integral bail strap while the power outlet is in use. While the power outlet is very similar to a cigar lighter base unit, it does not include the two small spring-clip retainers inside the bottom of the receptacle shell that are used to secure the cigar lighter heating element to the insulated contact. It has 12 volt battery voltage when the ignition is in the ON or ACC positions. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description and Operation > Description > Page 6101 Auxiliary Power Outlet: Description and Operation Operation OPERATION CIGAR LIGHTER/POWER OUTLET The cigar lighter consists of two major components: a knob and heating element unit, and the cigar lighter base or receptacle shell. The receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The cigar lighter knob and heating element are encased within a spring-loaded housing, which also features a sliding protective heat shield. When the knob and heating element are inserted in the receptacle shell, the heating element resistor coil is grounded through its housing to the receptacle shell. If the cigar lighter knob is pushed inward, the heat shield slides up toward the knob exposing the heating element, and the heating element extends from the housing toward the insulated contact in the bottom of the receptacle shell. Two small spring-clip retainers are located on either side of the insulated contact inside the bottom of the receptacle shell. These clips engage and hold the heating element against the insulated contact long enough for the resistor coil to heat up. When the heating element is engaged with the contact, battery current can flow through the resistor coil to ground, causing the resistor coil to heat. When the resistor coil becomes sufficiently heated, excess heat radiates from the heating element causing the spring-clips to expand. Once the spring-clips expand far enough to release the heating element, the spring-loaded housing forces the knob and heating element to pop back outward to their relaxed position. When the cigar lighter knob and element are pulled out of the receptacle shell, the protective heat shield slides downward on the housing so that the heating element is recessed and shielded around its circumference for safety. POWER OUTLET The power outlet base or receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The power outlet receives battery voltage from a fuse in the Totally Integrated Power Module (TIPM) through a fuse in the fuse block when the ignition is in the ON or ACC positions. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Cigar Lighter/Power Outlet Auxiliary Power Outlet: Service and Repair Cigar Lighter/Power Outlet Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Look inside and note position of the retaining bosses (1). 3. Using special tool 9857 Power Outlet Remover. Insert the tool forcing the bosses out of base. 4. Pull out the base through mounting ring by gently rocking the tool (3). 5. Disconnect the base wires. 6. Set base aside and remove base mount ring. Installation INSTALLATION 1. Position mount ring to the instrument panel and feed the wires through ring. Index the cap and the mount ring with the index tab at 9 o'clock to the key in the instrument panel. Install the ring. 2. Connect wires to base. Orient base alignment rib at 11 o'clock to mate the groove in mount ring at the same location. 3. Push base into the bezel till it locks. 4. Install cigar lighter cap. 5. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Cigar Lighter/Power Outlet > Page 6104 Auxiliary Power Outlet: Service and Repair Power Outlet-AC Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the center console. 3. Disconnect electrical connector. 4. Remove AC power outlet. Installation INSTALLATION 1. Install the AC power outlet. 2. Connect electrical connector. 3. Install the center console. 4. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Description and Operation > Description Electrical Accessory Panel: Description and Operation Description DESCRIPTION All of the electrical current distributed throughout this vehicle is directed through the standard equipment Totally Integrated Power Module (TIPM) (1). The molded plastic TIPM housing is located in the left front corner of the engine compartment, just behind the air cleaner housing and the battery. The TIPM housing has a molded plastic cover. The TIPM cover is easily removed for service access and has a convenient fuse and relay layout label affixed to the inside surface of the cover to ensure proper component identification. The TIPM housing is secured to the left inner fender well an indexing pin and one screw. All of the TIPM outputs are through the integral engine compartment wire harness. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Description and Operation > Description > Page 6109 Electrical Accessory Panel: Description and Operation Operation OPERATION All of the current from the generator cable connection goes to the battery through a 10 gauge fusible link that is secured with a nut to the positive battery terminal at the starter. Internal connection of all the Totally Integrated Power Module (TIPM) circuits is accomplished by an intricate network of hard wiring and bus bars. Refer to Wiring Diagrams for complete circuit diagrams. The fusible link, fuses and relays are available for service replacement. The TIPM unit cannot be repaired and is only serviced as a unit with the engine compartment wire harness. If the TIPM is inoperative or damaged, the engine compartment wire harness assembly must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Service and Repair > Removal Electrical Accessory Panel: Service and Repair Removal REMOVAL The TIPM (TIPM) is serviced as a unit with the engine compartment wire harness. If any internal circuit of the TIPM or the TIPM housing is faulty or damaged, the entire TIPM and engine compartment wire harness unit must be replaced. Refer to Wiring Diagrams for the locations of the affected connectors. 1. Open hood. 2. Disconnect and isolate the battery negative cable. 3. Disconnect each of the engine compartment wire harness connectors. 4. Remove the fasteners that secure each of the engine compartment wire harness ground eyelets to the vehicle body and chassis components. 5. Disengage each of the retainers that secure the engine compartment wire harness to the vehicle body and chassis components. 6. Disengage and remove the TIPM housing from its mounting bracket. 7. Remove the TIPM and the engine compartment wire harness from the engine compartment as a unit. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Service and Repair > Removal > Page 6112 Electrical Accessory Panel: Service and Repair Installation INSTALLATION The Totally Integrated Power Module (TIPM) is serviced as a unit with the engine compartment wire harness. If any internal circuit of the TIPM or the TIPM housing is faulty or damaged, the entire TIPM and engine compartment wire harness unit must be replaced. NOTE: If the Totally Integrated Power Module (TIPM) is being replaced with a new unit, be certain to transfer each of the fuses and relays from the old TIPM to the proper cavities of the new TIPM. Refer to Wiring Diagrams for the proper TIPM cavity assignments. 1. Position the TIPM in the engine compartment. 2. Align the TIPM on its mounting bracket and install. 3. Route the engine compartment wire harness from the TIPM through the engine compartment, engaging each of the harness retainers to the mounting provisions in the vehicle body and chassis components. Refer to Wiring Diagrams for the harness routing and retainer locations. 4. Install and tighten the fasteners that secure each of the engine compartment wire harness ground eyelets to the vehicle body and chassis components. Refer to Wiring Diagrams for the ground eyelet locations. 5. Reconnect each of the engine compartment wire harness connectors. Refer to Wiring Diagrams for the locations of the affected connectors. 6. Torque nut retaining positive battery cable at TIPM to 96 - 141 Nm (85 - 130 in. lbs.). 7. Reconnect the battery negative cable. 8. Close hood. 9. Verify vehicle and system operation. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Customer Interest for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems - Intermittent Component Operation Fuse: Customer Interest Electrical Systems - Intermittent Component Operation NUMBER:08-016-06 REV. A GROUP: Electrical DATE: July 18, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-016-06, DATED MARCH 22, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF A VEHICLE BODY STYLE. SUBJECT: Intermittent Operation Of Electrical Components Due To Ignition Off Draw (IOD) Fuse Not Being Fully Seated MODELS: 2007 (PM) Caliber **2007 (MK-49) Compass** 2006 - 2007 (DHIDRID1) Ram Truck 2006 - 2007 (PT) Chrysler PT Cruiser DISCUSSION: The Ignition Off Draw (IOD) fuse is used to prevent battery discharge during shipping and long term storage of the vehicles. The IOD fuse is located in the Total Integrated Power Module (TI PM). If the fuse is not completely inserted partial contact of the fuse terminals could occur. When the vehicle is prepped for customer delivery, ensure that the fuse is fully engaged (Fig. 1). The IOD fuse must also be fully released to prevent battery drain from occurring when the vehicle is stored. When the IOD fuse holder is depressed into the carrier, an initial distinct detent will be felt to overcome the "pre-hold position". You must then continue to push straight down on the IOD pre-holder until no further downward movement is encountered. NOTE: If the fuse is not pushed down symmetrically, two detents MAY be felt as each side snaps past the pre-hold position. Push down until no further downward movement is encountered. On 2006 and 2007 PT and PM vehicles the circuits fed by the IOD fuse are: Radio, Security module & siren (BUX), Wireless Control Module (RKE & SKREEM), Hands Free Module, Satellite Radio, Power Mirrors, Clock, Memory Seat, Amplifier, CCN wake-up with ignition off and Homelink. On 2006 and 2007 DR, DH or D1 vehicles the circuits fed by the IOD fuse are: Radio, EVIC, Wireless Control Module (RKE & SKREEM), Hands Free Module, Satellite Radio, Video Screen, CCN wake-up with ignition off, Underhood Lamp, CCN Interior Lighting Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Customer Interest for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems - Intermittent Component Operation > Page 6121 POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems - Intermittent Component Operation Fuse: All Technical Service Bulletins Electrical Systems - Intermittent Component Operation NUMBER:08-016-06 REV. A GROUP: Electrical DATE: July 18, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-016-06, DATED MARCH 22, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF A VEHICLE BODY STYLE. SUBJECT: Intermittent Operation Of Electrical Components Due To Ignition Off Draw (IOD) Fuse Not Being Fully Seated MODELS: 2007 (PM) Caliber **2007 (MK-49) Compass** 2006 - 2007 (DHIDRID1) Ram Truck 2006 - 2007 (PT) Chrysler PT Cruiser DISCUSSION: The Ignition Off Draw (IOD) fuse is used to prevent battery discharge during shipping and long term storage of the vehicles. The IOD fuse is located in the Total Integrated Power Module (TI PM). If the fuse is not completely inserted partial contact of the fuse terminals could occur. When the vehicle is prepped for customer delivery, ensure that the fuse is fully engaged (Fig. 1). The IOD fuse must also be fully released to prevent battery drain from occurring when the vehicle is stored. When the IOD fuse holder is depressed into the carrier, an initial distinct detent will be felt to overcome the "pre-hold position". You must then continue to push straight down on the IOD pre-holder until no further downward movement is encountered. NOTE: If the fuse is not pushed down symmetrically, two detents MAY be felt as each side snaps past the pre-hold position. Push down until no further downward movement is encountered. On 2006 and 2007 PT and PM vehicles the circuits fed by the IOD fuse are: Radio, Security module & siren (BUX), Wireless Control Module (RKE & SKREEM), Hands Free Module, Satellite Radio, Power Mirrors, Clock, Memory Seat, Amplifier, CCN wake-up with ignition off and Homelink. On 2006 and 2007 DR, DH or D1 vehicles the circuits fed by the IOD fuse are: Radio, EVIC, Wireless Control Module (RKE & SKREEM), Hands Free Module, Satellite Radio, Video Screen, CCN wake-up with ignition off, Underhood Lamp, CCN Interior Lighting Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems - Intermittent Component Operation > Page 6127 POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Page 6128 Fuse: Locations Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Page 6129 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Page 6130 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Page 6131 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Page 6132 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: Provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6135 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6136 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6137 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6138 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6139 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6140 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6141 5. Release the Secondary Terminal Lock, if required (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6142 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6143 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6144 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6145 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6146 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6147 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6148 Fuse: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6149 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6150 STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6151 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Page 6152 Fuse: Application and ID Totally Integrated Power Module Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Page 6153 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations Fuse Block: Locations Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Page 6157 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Page 6158 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Page 6159 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Page 6160 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: Provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6163 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6164 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6165 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6166 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6167 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6168 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6169 5. Release the Secondary Terminal Lock, if required (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6170 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6171 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6172 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6173 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6174 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6175 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6176 Fuse Block: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6177 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6178 STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6179 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 6180 Fuse Block: Application and ID Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 6181 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 6182 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 6183 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 6184 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Description and Operation > Description Fuse Block: Description and Operation Description DESCRIPTION An electrical Fuse Block is located in the left front bumper fascia. It serves to simplify and centralize numerous electrical components, as well as to distribute electrical current to many of the accessory systems in the vehicle. There are two clips that retain the fuse block cover to the fuse block. The cover can be removed to service the fuses and relays by depressing the clips and lifting off the cover. If fuse block wire terminal or insulator service is required the complete fuse block assembly must be removed. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Description and Operation > Description > Page 6187 Fuse Block: Description and Operation Operation OPERATION The fuse block houses relays and blade-type fuses. The fuses, relays and fuse block unit are available for service replacement. Refer to Wiring Diagrams for complete circuit diagrams. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Removal Fuse Block: Service and Repair Removal REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the front bumper fascia. 3. Depress mounting clips and lift the fuse block off the bracket. 4. Remove the wire harness and fuse block. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Removal > Page 6190 Fuse Block: Service and Repair Installation INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Install the new wire harness and fuse block into the vehicle. 2. Position the fuse block onto the mounting bracket and push down until the mounting clips are fully seated. 3. Install the front bumper fascia. 4. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Mini ISO Relay > Component Information > Service and Repair > Removal Mini ISO Relay: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove cover from Totally Integrated Power module (TIPM). 3. Using special tool C-4817 (1), grip the relay (2) by the sides and pull upward with an even effort. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Mini ISO Relay > Component Information > Service and Repair > Removal > Page 6195 Mini ISO Relay: Service and Repair Installation INSTALLATION 1. Align relay (2) with Totally Integrated Power Module (TIPM) and press into position. 2. Install cover to TIPM. 3. Connect battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Recalls: > G42 > Jan > 08 > Campaign - TIPM Software Update for Antitheft System Technical Service Bulletin # G42 Date: 080101 Campaign - TIPM Software Update for Antitheft System January 2008 Distributor/Dealer Service Instructions for: Customer Satisfaction Notice G42 TIPM Re-Configure, Anti-Theft System Models 2007 2008 (JS/PM/MK) Sebring, Avenger, Caliber, Compass and Patriot vehicles (International Markets Only) NOTE: This customer satisfaction notice applies only to the above vehicles built at the Sterling Heights Assembly Plant through July 25, 2007 (MDH 0725XX) and the Belvidere Assembly Plant through July 23, 2007 (MDH 0723XX). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this customer satisfaction notice. IMPORTANT: Some of the involved vehicles may be in distributor/dealer used vehicle inventory. Distributors/Dealers should complete this recall service on these vehicles before retail delivery. Distributors/Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Totally Integrated Power Module (TIPM) vehicles may be configured incorrectly preventing the Anti-Theft Security System from operating properly. Repair The Totally Integrated Power Module (TIPM) must be Re-Configured. Special Tools These existing special tools are required to perform this repair. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Recalls: > G42 > Jan > 08 > Campaign - TIPM Software Update for Antitheft System > Page 6204 Use the labor operation number and time allowance shown. Distributor/ Dealer Notification and Vehicle List Regional offices will receive an electronic list of involved vehicles. The Vehicle List is arranged by Distributor/Dealer code and in Vehicle Identification Number (VIN) sequence. The lists are for Distributor/Dealer reference in arranging for service of involved vehicles. Owner Notification and Service Scheduling All involved vehicle owners should be notified of the service requirement by their Distributor/Dealer. Owners are requested to schedule appointments for this service. A sample copy of the owner notification letter is included. Vehicle Lists, Global Recall System, VIP and Distributor/Dealer Follow up All involved vehicles have been entered into the Global Recall System (GRS) and Vehicle Information Plus (VIP) for Distributor/Dealer inquiry as needed. GRS provides involved Distributors/Dealers with an updated VIN list of their incomplete vehicles. Completed vehicles are removed from GRS within several days of repair claim submission. Distributors/Dealers must perform this repair on all unsold vehicles before retail delivery. Distributors/Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Additional Information If you have any questions or need assistance in completing this action, please contact your International Service and Parts Manager. Global Service & Parts - International Chrysler LLC Service Procedure NOTE: Use StarSCAN(R) to perform this Customer Satisfaction Notice. This procedure must be performed using software release 8.02 or higher. Re-Configure the TIPM using StarSCAN(R) 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN(R) Ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN® vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN(R). 5. Re-Configure the TIPM as Follows: a. With the StarSCAN(R) on the "Home" screen, select "ECU View". b. Select "TIPMCGW Central Gateway" in the list of modules. c. Select "Misc Functions". Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Recalls: > G42 > Jan > 08 > Campaign - TIPM Software Update for Antitheft System > Page 6205 d. Select "Restore Vehicle Configuration". e. Press "Start". f. Follow the prompts listed on the StarSCAN(R). g. When prompted, Enter the full 17 digit VIN found on the VIN plate. NOTE: Assure the correct VIN is input into the StarSCAN(R). h. Select "Next". NOTE: The StarSCAN(R) must be connected to the dealer network drop. i. Follow the prompts listed on the StarSCAN(R). 6. Check and clear any Diagnostic Trouble Codes (DTC's) that may have been set. 7. Turn the ignition key to the "OFF" position and remove the StarSCAN(R) unit, StarSCAN(R) cable, and battery charger from the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition Power Distribution Module: Customer Interest Antitheft System - Engine No Crank/No Start Condition NUMBER: 08-007-08 REV. A GROUP: Electrical DATE: July 04,2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-007-08, DATED MARCH 04, 2008. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. DO NOT ORDER PART NUMBER 05026070AP UNTIL JULY 21, 2008. ALL OTHER PART NUMBERS ARE AVAILABLE NOW. SUBJECT: No Engine Crank Or No Engine Start Due To Electronic Lockup Of The WCM / SKREEM OVERVIEW: This bulletin involves the replacement of the Wireless Control Module (WCM), and if equipped, the replacement of the Electric Steering Column Lock (ELV). The WCM is also referred to as the Sentry Key Remote Entry Module (SKREEM). MODELS: 2007 - 2008 (DR/DH/D1/DC/DM) Ram Truck (1500/2500/3500/4500/5500) 2007 - 2008 (JK) Wrangler 2007 - 2008 (J1) Sebring (China) 2007 - 2008 (JS) Avenger/Sebring 2007 - 2008 (KA) Nitro 2008 (KK) Liberty/Cherokee 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber 2006 - 2008 (PT) Chrysler PT Cruiser NOTE: This bulletin applies to vehicles built on or before May 05, 2008 (MDH 0505XX). SYMPTOM/CONDITION: The customer will experience a no engine crank AND a no engine start condition. Also, the remote keyless entry (RKE) system will not operate. This condition may be due to an electrostatic discharge (ESD) from the ignition key into the Wireless Control Module (WCM), causing the WCM to electronically lockup. This condition may occur more frequently in dry and/or cold weather conditions where a sufficient electrostatic charge is more easily produced. This condition is corrected by the replacement of the WCM. DIAGNOSIS: 1. With the condition present (i.e. the vehicle in the no crank / no start condition), connect the StarSCAN(R) scan tool to the vehicle. 2. Turn the ignition switch to the "ON position, and power up the StarSCAN(R). 3. If the WCM is electronically locked up, the StarSCAN(R) will display the WCM as being "off bus". 4. If the no crank / no start condition is present, and the WCM is "off bus", then reset the WCM by temporarily removing the IOD fuse (with the key out of the ignition switch), wait for 10 seconds and then reinstall the IOD fuse. 5. With the IOD fuse reset having been performed, verify that the vehicle will now crank, start, and run. 6. If the condition is temporarily corrected by performing the above steps, and if the part number of the WCM is earlier than the part number of the WCM listed in the part reference table in the Service Bulletin Parts Required Section below, then perform the Repair Procedure. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 6211 PARTS REQUIRED: NOTE: The part numbers listed in the following part reference table are to be used as A GUIDE to help determine if the WCM, that is currently in the vehicle, may require replacement. If it is determined that the WCM requires replacement, then ALWAYS REFER TO THE PARTS MANUAL to determine the correct WCM for the specific vehicle in question. In some earlier model years, the WCM may rule (supersede) to one of the part numbers listed in the table. ALWAYS REFER TO THE PARTS MANUAL (not the part reference table) to determine the correct part number ruling (supercedence / substitution). MAKE CERTAIN THAT THE CORRECT WCM IS ORDERED THE FIRST TIME FOR THE SPECIFIC VEHICLE IN QUESTION. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 6212 REPAIR PROCEDURE: NOTE: If the vehicle (a JS model vehicle in certain International markets) is equipped with an Electric Steering Column Lock (ELV), then the WCM and the ELV must be replaced. Replace the WCM and then the ELV. Next program the WCM and at least one (1) ignition key BEFORE programming the ELV. IMPORTANT: Not following this repair process correctly will cause the new ELV to fail. NOTE: Insert the ignition key into the ignition lock cylinder. This will move the shaft lock module locking bolt to the unlocked position. LEAVE the key in the lock cylinder while the shaft lock module is being removed. 1. If vehicle is equipped with a Steering Shaft Lock Module (JS - Avenger I Stratus - some International Markets), then the Shaft Lock Module will require replacement. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Security Information > Module, Shaft Lock > Removal and Installation. NOTE: The shaft lock module cannot be removed from the steering column while the locking bolt is in the locked position without irreversibly damaging the column. Before attempting service, the ignition key must have been inserted into the ignition lock cylinder. Then rotate the steering wheel from side to side. If the steering wheel can be rotated, the locking bolt is in the unlocked position. Leave the key in the ignition lock cylinder until shaft lock module removal has been completed. If the steering wheel cannot be rotated, test and repair the wiring circuits between the module and the ignition switch as required. If no problem is found in these circuits, the module has failed with the locking bolt in the locked position and both the module and the steering column must be replaced with new units. 2. Replace the WCM/SKREEM. Refer to TechCONNECT for detailed service information. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Service Information > Module, Sentry Key Remote Entry > Removal and Installation. NOTE: Obtain the vehicle PIN number prior to programming WCM/SKREEM or ELV. NOTE: If during the following steps the PIN number is properly entered but is rejected, then reenter the PIN number again until it is accepted. 3. After both the WCM/SKREEM and the ELV (if equipped) have been replaced, Program the WCM/SKREEM as follows: a. Turn the ignition key to the ON position, (Engine Off) b. Connect the scan tool (StarSCAN(R)) to the data link connector and turn the ignition to the RUN position, (engine off). c. Select "ECU View." d. Scroll down and select "WCM" in the list of modules. e. Select "Misc. Functions." f. Scroll to "WCM Replaced." g. Press "Start". h. Press "Next". i. Select "Show Keyboard". j. Enter the vehicle PIN number. k. Select "Next". l. Verify PIN is correct. m. Select "Next". n. Follow on-screen prompts to complete WCM function programing for Tire Pressure Monitoring (TPM) and so on. 0. Turn the ignition key to the OFF position. Wait 30 seconds. p. Turn the ignition key to the ON position, (Engine Off) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 6213 q. Select "ECU View". r. Scroll down and select "WCM" in the list of modules. s. Select "Misc. Functions." t. Select "Program Ign. Keys" and follow on-screen prompts. u. Select "Complete". v. Verify ignition key will start vehicle and the Remote Keyless Entry (RKE) functions operate. CAUTION: If the vehicle is equipped with a Shaft Lock Module (used in some International Markets on JS model vehicles), then at least one (1 ignition key must have been programmed to the new WCM BEFORE the new Shaft Lock Module is "married" to the new WCM. 4. Is the vehicle equipped with Steering Shaft Lock Module (ELV)? a. Yes >> Proceed to Step # 5. b. No >>Repair is complete. 5. Program the ELV as follows; a. Select "ECU View". b. Scroll down and select "WCM" in the list of modules. c. Select "Misc. Functions". d. Scroll to "ELV Replaced." e. Press "Start". f. When complete, verify steering shaft lock mechanism is operating. Remove and insert key from the ignition lock cylinder and listen for solenoid "click at lower end of column. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 6214 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition Power Distribution Module: All Technical Service Bulletins Antitheft System - Engine No Crank/No Start Condition NUMBER: 08-007-08 REV. A GROUP: Electrical DATE: July 04,2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-007-08, DATED MARCH 04, 2008. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. DO NOT ORDER PART NUMBER 05026070AP UNTIL JULY 21, 2008. ALL OTHER PART NUMBERS ARE AVAILABLE NOW. SUBJECT: No Engine Crank Or No Engine Start Due To Electronic Lockup Of The WCM / SKREEM OVERVIEW: This bulletin involves the replacement of the Wireless Control Module (WCM), and if equipped, the replacement of the Electric Steering Column Lock (ELV). The WCM is also referred to as the Sentry Key Remote Entry Module (SKREEM). MODELS: 2007 - 2008 (DR/DH/D1/DC/DM) Ram Truck (1500/2500/3500/4500/5500) 2007 - 2008 (JK) Wrangler 2007 - 2008 (J1) Sebring (China) 2007 - 2008 (JS) Avenger/Sebring 2007 - 2008 (KA) Nitro 2008 (KK) Liberty/Cherokee 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber 2006 - 2008 (PT) Chrysler PT Cruiser NOTE: This bulletin applies to vehicles built on or before May 05, 2008 (MDH 0505XX). SYMPTOM/CONDITION: The customer will experience a no engine crank AND a no engine start condition. Also, the remote keyless entry (RKE) system will not operate. This condition may be due to an electrostatic discharge (ESD) from the ignition key into the Wireless Control Module (WCM), causing the WCM to electronically lockup. This condition may occur more frequently in dry and/or cold weather conditions where a sufficient electrostatic charge is more easily produced. This condition is corrected by the replacement of the WCM. DIAGNOSIS: 1. With the condition present (i.e. the vehicle in the no crank / no start condition), connect the StarSCAN(R) scan tool to the vehicle. 2. Turn the ignition switch to the "ON position, and power up the StarSCAN(R). 3. If the WCM is electronically locked up, the StarSCAN(R) will display the WCM as being "off bus". 4. If the no crank / no start condition is present, and the WCM is "off bus", then reset the WCM by temporarily removing the IOD fuse (with the key out of the ignition switch), wait for 10 seconds and then reinstall the IOD fuse. 5. With the IOD fuse reset having been performed, verify that the vehicle will now crank, start, and run. 6. If the condition is temporarily corrected by performing the above steps, and if the part number of the WCM is earlier than the part number of the WCM listed in the part reference table in the Service Bulletin Parts Required Section below, then perform the Repair Procedure. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 6220 PARTS REQUIRED: NOTE: The part numbers listed in the following part reference table are to be used as A GUIDE to help determine if the WCM, that is currently in the vehicle, may require replacement. If it is determined that the WCM requires replacement, then ALWAYS REFER TO THE PARTS MANUAL to determine the correct WCM for the specific vehicle in question. In some earlier model years, the WCM may rule (supersede) to one of the part numbers listed in the table. ALWAYS REFER TO THE PARTS MANUAL (not the part reference table) to determine the correct part number ruling (supercedence / substitution). MAKE CERTAIN THAT THE CORRECT WCM IS ORDERED THE FIRST TIME FOR THE SPECIFIC VEHICLE IN QUESTION. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 6221 REPAIR PROCEDURE: NOTE: If the vehicle (a JS model vehicle in certain International markets) is equipped with an Electric Steering Column Lock (ELV), then the WCM and the ELV must be replaced. Replace the WCM and then the ELV. Next program the WCM and at least one (1) ignition key BEFORE programming the ELV. IMPORTANT: Not following this repair process correctly will cause the new ELV to fail. NOTE: Insert the ignition key into the ignition lock cylinder. This will move the shaft lock module locking bolt to the unlocked position. LEAVE the key in the lock cylinder while the shaft lock module is being removed. 1. If vehicle is equipped with a Steering Shaft Lock Module (JS - Avenger I Stratus - some International Markets), then the Shaft Lock Module will require replacement. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Security Information > Module, Shaft Lock > Removal and Installation. NOTE: The shaft lock module cannot be removed from the steering column while the locking bolt is in the locked position without irreversibly damaging the column. Before attempting service, the ignition key must have been inserted into the ignition lock cylinder. Then rotate the steering wheel from side to side. If the steering wheel can be rotated, the locking bolt is in the unlocked position. Leave the key in the ignition lock cylinder until shaft lock module removal has been completed. If the steering wheel cannot be rotated, test and repair the wiring circuits between the module and the ignition switch as required. If no problem is found in these circuits, the module has failed with the locking bolt in the locked position and both the module and the steering column must be replaced with new units. 2. Replace the WCM/SKREEM. Refer to TechCONNECT for detailed service information. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Service Information > Module, Sentry Key Remote Entry > Removal and Installation. NOTE: Obtain the vehicle PIN number prior to programming WCM/SKREEM or ELV. NOTE: If during the following steps the PIN number is properly entered but is rejected, then reenter the PIN number again until it is accepted. 3. After both the WCM/SKREEM and the ELV (if equipped) have been replaced, Program the WCM/SKREEM as follows: a. Turn the ignition key to the ON position, (Engine Off) b. Connect the scan tool (StarSCAN(R)) to the data link connector and turn the ignition to the RUN position, (engine off). c. Select "ECU View." d. Scroll down and select "WCM" in the list of modules. e. Select "Misc. Functions." f. Scroll to "WCM Replaced." g. Press "Start". h. Press "Next". i. Select "Show Keyboard". j. Enter the vehicle PIN number. k. Select "Next". l. Verify PIN is correct. m. Select "Next". n. Follow on-screen prompts to complete WCM function programing for Tire Pressure Monitoring (TPM) and so on. 0. Turn the ignition key to the OFF position. Wait 30 seconds. p. Turn the ignition key to the ON position, (Engine Off) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 6222 q. Select "ECU View". r. Scroll down and select "WCM" in the list of modules. s. Select "Misc. Functions." t. Select "Program Ign. Keys" and follow on-screen prompts. u. Select "Complete". v. Verify ignition key will start vehicle and the Remote Keyless Entry (RKE) functions operate. CAUTION: If the vehicle is equipped with a Shaft Lock Module (used in some International Markets on JS model vehicles), then at least one (1 ignition key must have been programmed to the new WCM BEFORE the new Shaft Lock Module is "married" to the new WCM. 4. Is the vehicle equipped with Steering Shaft Lock Module (ELV)? a. Yes >> Proceed to Step # 5. b. No >>Repair is complete. 5. Program the ELV as follows; a. Select "ECU View". b. Scroll down and select "WCM" in the list of modules. c. Select "Misc. Functions". d. Scroll to "ELV Replaced." e. Press "Start". f. When complete, verify steering shaft lock mechanism is operating. Remove and insert key from the ignition lock cylinder and listen for solenoid "click at lower end of column. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 6223 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > G42 > Jan > 08 > Campaign TIPM Software Update for Antitheft System Technical Service Bulletin # G42 Date: 080101 Campaign - TIPM Software Update for Antitheft System January 2008 Distributor/Dealer Service Instructions for: Customer Satisfaction Notice G42 TIPM Re-Configure, Anti-Theft System Models 2007 2008 (JS/PM/MK) Sebring, Avenger, Caliber, Compass and Patriot vehicles (International Markets Only) NOTE: This customer satisfaction notice applies only to the above vehicles built at the Sterling Heights Assembly Plant through July 25, 2007 (MDH 0725XX) and the Belvidere Assembly Plant through July 23, 2007 (MDH 0723XX). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this customer satisfaction notice. IMPORTANT: Some of the involved vehicles may be in distributor/dealer used vehicle inventory. Distributors/Dealers should complete this recall service on these vehicles before retail delivery. Distributors/Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Totally Integrated Power Module (TIPM) vehicles may be configured incorrectly preventing the Anti-Theft Security System from operating properly. Repair The Totally Integrated Power Module (TIPM) must be Re-Configured. Special Tools These existing special tools are required to perform this repair. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > G42 > Jan > 08 > Campaign TIPM Software Update for Antitheft System > Page 6228 Use the labor operation number and time allowance shown. Distributor/ Dealer Notification and Vehicle List Regional offices will receive an electronic list of involved vehicles. The Vehicle List is arranged by Distributor/Dealer code and in Vehicle Identification Number (VIN) sequence. The lists are for Distributor/Dealer reference in arranging for service of involved vehicles. Owner Notification and Service Scheduling All involved vehicle owners should be notified of the service requirement by their Distributor/Dealer. Owners are requested to schedule appointments for this service. A sample copy of the owner notification letter is included. Vehicle Lists, Global Recall System, VIP and Distributor/Dealer Follow up All involved vehicles have been entered into the Global Recall System (GRS) and Vehicle Information Plus (VIP) for Distributor/Dealer inquiry as needed. GRS provides involved Distributors/Dealers with an updated VIN list of their incomplete vehicles. Completed vehicles are removed from GRS within several days of repair claim submission. Distributors/Dealers must perform this repair on all unsold vehicles before retail delivery. Distributors/Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Additional Information If you have any questions or need assistance in completing this action, please contact your International Service and Parts Manager. Global Service & Parts - International Chrysler LLC Service Procedure NOTE: Use StarSCAN(R) to perform this Customer Satisfaction Notice. This procedure must be performed using software release 8.02 or higher. Re-Configure the TIPM using StarSCAN(R) 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN(R) Ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN® vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN(R). 5. Re-Configure the TIPM as Follows: a. With the StarSCAN(R) on the "Home" screen, select "ECU View". b. Select "TIPMCGW Central Gateway" in the list of modules. c. Select "Misc Functions". Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > G42 > Jan > 08 > Campaign TIPM Software Update for Antitheft System > Page 6229 d. Select "Restore Vehicle Configuration". e. Press "Start". f. Follow the prompts listed on the StarSCAN(R). g. When prompted, Enter the full 17 digit VIN found on the VIN plate. NOTE: Assure the correct VIN is input into the StarSCAN(R). h. Select "Next". NOTE: The StarSCAN(R) must be connected to the dealer network drop. i. Follow the prompts listed on the StarSCAN(R). 6. Check and clear any Diagnostic Trouble Codes (DTC's) that may have been set. 7. Turn the ignition key to the "OFF" position and remove the StarSCAN(R) unit, StarSCAN(R) cable, and battery charger from the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition Power Distribution Module: All Technical Service Bulletins Antitheft System - Engine No Crank/No Start Condition NUMBER: 08-007-08 REV. A GROUP: Electrical DATE: July 04,2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-007-08, DATED MARCH 04, 2008. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. DO NOT ORDER PART NUMBER 05026070AP UNTIL JULY 21, 2008. ALL OTHER PART NUMBERS ARE AVAILABLE NOW. SUBJECT: No Engine Crank Or No Engine Start Due To Electronic Lockup Of The WCM / SKREEM OVERVIEW: This bulletin involves the replacement of the Wireless Control Module (WCM), and if equipped, the replacement of the Electric Steering Column Lock (ELV). The WCM is also referred to as the Sentry Key Remote Entry Module (SKREEM). MODELS: 2007 - 2008 (DR/DH/D1/DC/DM) Ram Truck (1500/2500/3500/4500/5500) 2007 - 2008 (JK) Wrangler 2007 - 2008 (J1) Sebring (China) 2007 - 2008 (JS) Avenger/Sebring 2007 - 2008 (KA) Nitro 2008 (KK) Liberty/Cherokee 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber 2006 - 2008 (PT) Chrysler PT Cruiser NOTE: This bulletin applies to vehicles built on or before May 05, 2008 (MDH 0505XX). SYMPTOM/CONDITION: The customer will experience a no engine crank AND a no engine start condition. Also, the remote keyless entry (RKE) system will not operate. This condition may be due to an electrostatic discharge (ESD) from the ignition key into the Wireless Control Module (WCM), causing the WCM to electronically lockup. This condition may occur more frequently in dry and/or cold weather conditions where a sufficient electrostatic charge is more easily produced. This condition is corrected by the replacement of the WCM. DIAGNOSIS: 1. With the condition present (i.e. the vehicle in the no crank / no start condition), connect the StarSCAN(R) scan tool to the vehicle. 2. Turn the ignition switch to the "ON position, and power up the StarSCAN(R). 3. If the WCM is electronically locked up, the StarSCAN(R) will display the WCM as being "off bus". 4. If the no crank / no start condition is present, and the WCM is "off bus", then reset the WCM by temporarily removing the IOD fuse (with the key out of the ignition switch), wait for 10 seconds and then reinstall the IOD fuse. 5. With the IOD fuse reset having been performed, verify that the vehicle will now crank, start, and run. 6. If the condition is temporarily corrected by performing the above steps, and if the part number of the WCM is earlier than the part number of the WCM listed in the part reference table in the Service Bulletin Parts Required Section below, then perform the Repair Procedure. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 6235 PARTS REQUIRED: NOTE: The part numbers listed in the following part reference table are to be used as A GUIDE to help determine if the WCM, that is currently in the vehicle, may require replacement. If it is determined that the WCM requires replacement, then ALWAYS REFER TO THE PARTS MANUAL to determine the correct WCM for the specific vehicle in question. In some earlier model years, the WCM may rule (supersede) to one of the part numbers listed in the table. ALWAYS REFER TO THE PARTS MANUAL (not the part reference table) to determine the correct part number ruling (supercedence / substitution). MAKE CERTAIN THAT THE CORRECT WCM IS ORDERED THE FIRST TIME FOR THE SPECIFIC VEHICLE IN QUESTION. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 6236 REPAIR PROCEDURE: NOTE: If the vehicle (a JS model vehicle in certain International markets) is equipped with an Electric Steering Column Lock (ELV), then the WCM and the ELV must be replaced. Replace the WCM and then the ELV. Next program the WCM and at least one (1) ignition key BEFORE programming the ELV. IMPORTANT: Not following this repair process correctly will cause the new ELV to fail. NOTE: Insert the ignition key into the ignition lock cylinder. This will move the shaft lock module locking bolt to the unlocked position. LEAVE the key in the lock cylinder while the shaft lock module is being removed. 1. If vehicle is equipped with a Steering Shaft Lock Module (JS - Avenger I Stratus - some International Markets), then the Shaft Lock Module will require replacement. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Security Information > Module, Shaft Lock > Removal and Installation. NOTE: The shaft lock module cannot be removed from the steering column while the locking bolt is in the locked position without irreversibly damaging the column. Before attempting service, the ignition key must have been inserted into the ignition lock cylinder. Then rotate the steering wheel from side to side. If the steering wheel can be rotated, the locking bolt is in the unlocked position. Leave the key in the ignition lock cylinder until shaft lock module removal has been completed. If the steering wheel cannot be rotated, test and repair the wiring circuits between the module and the ignition switch as required. If no problem is found in these circuits, the module has failed with the locking bolt in the locked position and both the module and the steering column must be replaced with new units. 2. Replace the WCM/SKREEM. Refer to TechCONNECT for detailed service information. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Service Information > Module, Sentry Key Remote Entry > Removal and Installation. NOTE: Obtain the vehicle PIN number prior to programming WCM/SKREEM or ELV. NOTE: If during the following steps the PIN number is properly entered but is rejected, then reenter the PIN number again until it is accepted. 3. After both the WCM/SKREEM and the ELV (if equipped) have been replaced, Program the WCM/SKREEM as follows: a. Turn the ignition key to the ON position, (Engine Off) b. Connect the scan tool (StarSCAN(R)) to the data link connector and turn the ignition to the RUN position, (engine off). c. Select "ECU View." d. Scroll down and select "WCM" in the list of modules. e. Select "Misc. Functions." f. Scroll to "WCM Replaced." g. Press "Start". h. Press "Next". i. Select "Show Keyboard". j. Enter the vehicle PIN number. k. Select "Next". l. Verify PIN is correct. m. Select "Next". n. Follow on-screen prompts to complete WCM function programing for Tire Pressure Monitoring (TPM) and so on. 0. Turn the ignition key to the OFF position. Wait 30 seconds. p. Turn the ignition key to the ON position, (Engine Off) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 6237 q. Select "ECU View". r. Scroll down and select "WCM" in the list of modules. s. Select "Misc. Functions." t. Select "Program Ign. Keys" and follow on-screen prompts. u. Select "Complete". v. Verify ignition key will start vehicle and the Remote Keyless Entry (RKE) functions operate. CAUTION: If the vehicle is equipped with a Shaft Lock Module (used in some International Markets on JS model vehicles), then at least one (1 ignition key must have been programmed to the new WCM BEFORE the new Shaft Lock Module is "married" to the new WCM. 4. Is the vehicle equipped with Steering Shaft Lock Module (ELV)? a. Yes >> Proceed to Step # 5. b. No >>Repair is complete. 5. Program the ELV as follows; a. Select "ECU View". b. Scroll down and select "WCM" in the list of modules. c. Select "Misc. Functions". d. Scroll to "ELV Replaced." e. Press "Start". f. When complete, verify steering shaft lock mechanism is operating. Remove and insert key from the ignition lock cylinder and listen for solenoid "click at lower end of column. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 6238 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Distribution Module: > G42 > Jan > 08 > Campaign TIPM Software Update for Antitheft System Technical Service Bulletin # G42 Date: 080101 Campaign - TIPM Software Update for Antitheft System January 2008 Distributor/Dealer Service Instructions for: Customer Satisfaction Notice G42 TIPM Re-Configure, Anti-Theft System Models 2007 2008 (JS/PM/MK) Sebring, Avenger, Caliber, Compass and Patriot vehicles (International Markets Only) NOTE: This customer satisfaction notice applies only to the above vehicles built at the Sterling Heights Assembly Plant through July 25, 2007 (MDH 0725XX) and the Belvidere Assembly Plant through July 23, 2007 (MDH 0723XX). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this customer satisfaction notice. IMPORTANT: Some of the involved vehicles may be in distributor/dealer used vehicle inventory. Distributors/Dealers should complete this recall service on these vehicles before retail delivery. Distributors/Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Totally Integrated Power Module (TIPM) vehicles may be configured incorrectly preventing the Anti-Theft Security System from operating properly. Repair The Totally Integrated Power Module (TIPM) must be Re-Configured. Special Tools These existing special tools are required to perform this repair. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Distribution Module: > G42 > Jan > 08 > Campaign TIPM Software Update for Antitheft System > Page 6244 Use the labor operation number and time allowance shown. Distributor/ Dealer Notification and Vehicle List Regional offices will receive an electronic list of involved vehicles. The Vehicle List is arranged by Distributor/Dealer code and in Vehicle Identification Number (VIN) sequence. The lists are for Distributor/Dealer reference in arranging for service of involved vehicles. Owner Notification and Service Scheduling All involved vehicle owners should be notified of the service requirement by their Distributor/Dealer. Owners are requested to schedule appointments for this service. A sample copy of the owner notification letter is included. Vehicle Lists, Global Recall System, VIP and Distributor/Dealer Follow up All involved vehicles have been entered into the Global Recall System (GRS) and Vehicle Information Plus (VIP) for Distributor/Dealer inquiry as needed. GRS provides involved Distributors/Dealers with an updated VIN list of their incomplete vehicles. Completed vehicles are removed from GRS within several days of repair claim submission. Distributors/Dealers must perform this repair on all unsold vehicles before retail delivery. Distributors/Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Additional Information If you have any questions or need assistance in completing this action, please contact your International Service and Parts Manager. Global Service & Parts - International Chrysler LLC Service Procedure NOTE: Use StarSCAN(R) to perform this Customer Satisfaction Notice. This procedure must be performed using software release 8.02 or higher. Re-Configure the TIPM using StarSCAN(R) 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN(R) Ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN® vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN(R). 5. Re-Configure the TIPM as Follows: a. With the StarSCAN(R) on the "Home" screen, select "ECU View". b. Select "TIPMCGW Central Gateway" in the list of modules. c. Select "Misc Functions". Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Distribution Module: > G42 > Jan > 08 > Campaign TIPM Software Update for Antitheft System > Page 6245 d. Select "Restore Vehicle Configuration". e. Press "Start". f. Follow the prompts listed on the StarSCAN(R). g. When prompted, Enter the full 17 digit VIN found on the VIN plate. NOTE: Assure the correct VIN is input into the StarSCAN(R). h. Select "Next". NOTE: The StarSCAN(R) must be connected to the dealer network drop. i. Follow the prompts listed on the StarSCAN(R). 6. Check and clear any Diagnostic Trouble Codes (DTC's) that may have been set. 7. Turn the ignition key to the "OFF" position and remove the StarSCAN(R) unit, StarSCAN(R) cable, and battery charger from the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead Power Distribution Module: Locations Module-Electronic Overhead Component ID: 148 Component : MODULE-ELECTRONIC OVERHEAD Connector: Name : MODULE-ELECTRONIC OVERHEAD C1 Color : BLACK # of pins : 3 A READING/RAIL LAMPS DRIVER M27 20YL/LB B GROUND Z936 20BK/LB C COURTESY LAMPS DRIVER M24 20YL/WT Component Location - 43 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6248 Connector: Name : MODULE-ELECTRONIC OVERHEAD C2 Color : BLACK # of pins : 4 A SUNROOF VENT SWITCH SENSE Q4 20OR/YL B SUNROOF SWITCH SUPPLY Q6 20OR/LG C SUNROOF OPEN SWITCH SENSE Q3 20OR/TN D SUNROOF CLOSE SWITCH SENSE Q5 20OR/LB Component Location - 43 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6249 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6250 Power Distribution Module: Locations Module-Totally Integrated Power Component ID: 163 Component : MODULE-TOTALLY INTEGRATED POWER Connector: Name : MODULE-TOTALLY INTEGRATED POWER C1 Color : BLACK # of pins : 13 Pin Description Circuit 1 REAR WASHER PUMP MOTOR CONTROL W20 20BR/YL 2 FRONT WASHER PUMP MOTOR CONTROL W10 20BR/TN 3 IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4-5-6 CABIN HEATER RELAY 2 CONTROL K232 20BR/LB 7 CABIN HEATER RELAY 1 CONTROL K132 20DB/LB 8-9-10 - 11 - 12 BRAKE FLUID LEVEL SWITCH SENSE B20 20DG/RD 13 GROUND Z924 20BK/LB Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6251 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6252 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C10 Color : LT. GRAY # of pins : 8 Pin Description Circuit 1-2-3 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 4-5 FUSED MAIN RELAY OUTPUT F343 18DB/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6253 6 FUSED MAIN RELAY OUTPUT F344 18DB/LB 7-8 STARTER CONTROL OUTPUT T750 16YL/GY Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6254 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C11 Color : GREEN # of pins : 22 Pin Description Circuit 1 FUSED MAIN RELAY OUTPUT F342 14BR/DG 2-3-4 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 5 FRONT FOG LAMP CONTROL OUTPUT L89 20WT/YL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6255 6 FRONT FOG LAMP CONTROL OUTPUT L90 20WT/OR 7 LOW/HIGH RAD FAN RELAY CONTROL N201 20DB/LG 8 HORN CONTROL OUTPUT X22 20GY/LB 9 HORN CONTROL OUTPUT X21 20GY/YL 10 FRONT WIPER HIGH SPEED CONTROL OUTPUT W4 16BR/LB 11 FUSED B(+) A935 20RD/LB 12 FRONT WIPER LOW SPEED CONTROL OUTPUT W3 16BR/WT 13 FUSED IGNITION SWITCH OUTPUT (RUN) F936 20PK/YL 14 FUSED B(+) (VALVE) A922 14RD/BK 15 - 16 - - 17 FUSED B(+) (PUMP) A921 12RD/DB 18 - 19 FUSED B(+) A931 20RD/WT 20 - 21 GROUND Z971 16BK 22 RAD FAN RELAY CONTROL N112 20DB/OR Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6256 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C2 Color : LT. GRAY # of pins : 14 Pin Description Circuit 1 IGNITION SWITCH OUTPUT (UNLOCK-RUN-START) F901 20PK/RD 2 STARTER CONTROL T752 20DG/OR 3-4 FUEL PUMP CONTROL K31 20DB/BK 4 FUEL PUMP CONTROL K31 20BR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6257 5 FRONT WIPER PARK SWITCH SENSE W7 20BR/DB 6 GROUND Z924 20BK/LB 7 CAN C BUS (+) D265 20WT/BK 8-9-10 IGNITION SWITCH OUTPUT (UNLOCK-RUN-START) F901 20PK/RD 11 HOOD AJAR SWITCH SENSE G70 20VT/LB 12 - 13 GROUND Z925 20BK/YL 14 CAN C BUS (-) D264 20DB/WT Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6258 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C3 Color : BROWN # of pins : 16 Pin Description Circuit 1 CAN C BUS (+) D65 20WT/BK 2 DIAGNOSTIC CAN C (+) D72 20WT/TN 3 CAN B BUS (+) D55 20WT/OR 4 LEFT REAR TURN SIGNAL L63 20DG/RD 5-- Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6259 6 RIGHT REAR TURN SIGNAL L62 20WT/YL 7 STOP LAMP SWITCH OUTPUT L53 20DG/WT 8 PARK LAMP CONTROL OUTPUT L217 20WT/VT 9 CAN C BUS (-) D64 20WT/LB 10 DIAGNOSTIC CAN C (-) D71 20WT/DB 11 CAN B BUS (-) D54 20WT/PK 12 IGNITION SWITCH OUTPUT (START) F961 20PK/LB 13 STOP LAMP CONTROL OUTPUT L55 20WT/OR 14 - 15 RIGHT REAR WHEEL SPEED SENSOR SIGNAL B1 20YL/DB 16 RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY B2 20DG/TN Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6260 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C4 Color : BLACK # of pins : 10 Pin Description Circuit 1 LEFT TURN SIGNAL L61 20WT/RD 2 RIGHT TURN SIGNAL L60 20WT/TN 3 RIGHT HIGH BEAM OUTPUT L34 20WT/GY 4 LEFT LOW BEAM OUTPUT L43 20WT/DB 5-- Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6261 6-7-8 AAT SIGNAL G31 20VT/LG 9 AAT RETURN G931 20VT/DB 10 - Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6262 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C5 Color : BLUE # of pins : 14 Pin Description Circuit 1 HEADLAMP SWITCH OUTPUT L70 20WT/GY 2 RIGHT TURN SIGNAL (OUT) L160 20WT/TN 3 RIGHT LOW BEAM OUTPUT L44 20VT/RD 4 LEFT HIGH BEAM OUTPUT L33 20WT/PK 5 LEFT TURN SIGNAL (OUT) L161 20WT/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6263 6 HEADLAMP SWITCH OUTPUT L7 20WT/VT 6 HEADLAMP SWITCH OUTPUT L7 20WT/YL 7 A/C PRESSURE SENSOR SUPPLY C818 20LB/TN 8 BACKUP LAMP SWITCH SIGNAL T22 20YL/VT 9 HEADLAMP LEVEL SENSOR SIGNAL L131 20WT/LG 10 HEADLAMP LEVEL SENSOR SIGNAL L132 20LG/WT 11 - 12 A/C PRESSURE SENSOR SIGNAL C18 20LB/BR 13 A/C PRESSURE SENSOR GROUND C918 20BK/LB 14 IGNITION SWITCH OUTPUT (START) F962 20PK/BK Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6264 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C6 Color : LT. GRAY # of pins : 13 Pin Description Circuit 1-2-3-4-5 REAR WIPER MOTOR CONTROL W13 20BR/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6265 6-7-8-9-10 - 11 - 12 REAR FOG LAMP CONTROL OUTPUT L239 20WT/DG 13 - Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6266 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C7 Color : LT. GRAY # of pins : 22 Pin Description Circuit 1-2 FUSED B(+) A923 18RD/WT 2 FUSED B(+) A923 20RD/WT 3 FUSED B(+) A924 20DG/WT 4 FUSED B(+) A952 20RD/OR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6267 5 FUSED IGNITION SWITCH OUTPUT (RUN-START) F200 20PK/LB 6 FUSED B(+) A100 18RD/VT 7 FUSED IGNITION SWITCH OUTPUT (RUN) F100 20DG/YL 8-9 FUSED B(+) A933 20RD/LG 10 - 11 FUEL PUMP CONTROL OUTPUT N1 16DB/OR 12 - 13 FUSED B(+) (I.O.D.) A417 20RD/DG 14 - 15 FUSED B(+) (I.O.D.) A418 20RD/BK 16 FUSED B(+) (I.O.D.) A412 20RD/DB 17 FUSED B(+) A16 12RD/BR 18 DOOR LOCK POWER-FUSED B(+) A932 18RD/BR 19 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F996 20PK/YL 20 - 21 IGNITION SWITCH OUTPUT (RUN-ACC) F981 14PK/BR 22 FUSED B(+) A999 18RD/PK Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6268 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C8 Color : BLACK # of pins : 22 Pin Description Circuit 1 BLOWER MOTOR CONTROL C7 12DB/PK 2 FUSED B(+) A927 16RD/GY 3 FUSED B(+) (I.O.D.) A415 20RD/TN 4 FUSED B(+) (I.O.D.) A414 20RD/DG 5 FUSED B(+) (I.O.D.) A416 18RD Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6269 6 FUSED B(+) (I.O.D.) A420 18WT/RD 7 FUSED B(+) A14 12RD/YL 8 FUSED IGNITION SWITCH OUTPUT (RUN) F937 18PK/YL 9 FUSED REAR WINDOW DEFOGGER CONTROL OUTPUT C16 20DB/GY 10 - 11 BACKUP LAMP SWITCH OUTPUT L1 20WT/LG 12 FUSED IGNITION SWITCH OUTPUT (RUN) F929 20PK/RD 13 FUSED B(+) (I.O.D.) A411 20RD/LG 14 FUSED B(+) (I.O.D.) A419 18RD/DG 15 - 16 - - 17 REAR WINDOW DEFOGGER CONTROL OUTPUT C515 12LB/OR 18 FUSED B(+) (I.O.D.) A413 18RD/LB 19 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 20 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F985 18PK/YL 21 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F986 20PK/BK 22 MAIN RELAY OUTPUT K542 12BR/WT Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6270 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C9 Color : # of pins : 1 Pin Description Circuit 1 B(+) A0 6RD Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6271 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6272 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6273 Power Distribution Module: Locations Module-Inverter Component ID: 157 Component : MODULE-INVERTER Connector: Name : MODULE-INVERTER Color : # of pins : 9 Qualifier : (EXCEPT EXPORT) Pin Description Circuit 1 FUSED B(+) A999 16RD/PK 2-3 110 VOLT AC LINE 1 P801 18LG/PK 4 GROUND Z940 14BK/LG 5 INVERTER ENABLE SWITCH SIGNAL P805 18LG/DB 6-- 7-8 110 VOLT AC COMMON P809 18LG/LB 9-Component Location - 24 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6274 Component Location - 26 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6275 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead Power Distribution Module: Diagrams Module-Electronic Overhead Component ID: 148 Component : MODULE-ELECTRONIC OVERHEAD Connector: Name : MODULE-ELECTRONIC OVERHEAD C1 Color : BLACK # of pins : 3 A READING/RAIL LAMPS DRIVER M27 20YL/LB B GROUND Z936 20BK/LB C COURTESY LAMPS DRIVER M24 20YL/WT Component Location - 43 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6278 Connector: Name : MODULE-ELECTRONIC OVERHEAD C2 Color : BLACK # of pins : 4 A SUNROOF VENT SWITCH SENSE Q4 20OR/YL B SUNROOF SWITCH SUPPLY Q6 20OR/LG C SUNROOF OPEN SWITCH SENSE Q3 20OR/TN D SUNROOF CLOSE SWITCH SENSE Q5 20OR/LB Component Location - 43 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6279 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6280 Power Distribution Module: Diagrams Module-Totally Integrated Power Component ID: 163 Component : MODULE-TOTALLY INTEGRATED POWER Connector: Name : MODULE-TOTALLY INTEGRATED POWER C1 Color : BLACK # of pins : 13 Pin Description Circuit 1 REAR WASHER PUMP MOTOR CONTROL W20 20BR/YL 2 FRONT WASHER PUMP MOTOR CONTROL W10 20BR/TN 3 IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4-5-6 CABIN HEATER RELAY 2 CONTROL K232 20BR/LB 7 CABIN HEATER RELAY 1 CONTROL K132 20DB/LB 8-9-10 - 11 - 12 BRAKE FLUID LEVEL SWITCH SENSE B20 20DG/RD 13 GROUND Z924 20BK/LB Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6281 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6282 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C10 Color : LT. GRAY # of pins : 8 Pin Description Circuit 1-2-3 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 4-5 FUSED MAIN RELAY OUTPUT F343 18DB/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6283 6 FUSED MAIN RELAY OUTPUT F344 18DB/LB 7-8 STARTER CONTROL OUTPUT T750 16YL/GY Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6284 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C11 Color : GREEN # of pins : 22 Pin Description Circuit 1 FUSED MAIN RELAY OUTPUT F342 14BR/DG 2-3-4 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 5 FRONT FOG LAMP CONTROL OUTPUT L89 20WT/YL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6285 6 FRONT FOG LAMP CONTROL OUTPUT L90 20WT/OR 7 LOW/HIGH RAD FAN RELAY CONTROL N201 20DB/LG 8 HORN CONTROL OUTPUT X22 20GY/LB 9 HORN CONTROL OUTPUT X21 20GY/YL 10 FRONT WIPER HIGH SPEED CONTROL OUTPUT W4 16BR/LB 11 FUSED B(+) A935 20RD/LB 12 FRONT WIPER LOW SPEED CONTROL OUTPUT W3 16BR/WT 13 FUSED IGNITION SWITCH OUTPUT (RUN) F936 20PK/YL 14 FUSED B(+) (VALVE) A922 14RD/BK 15 - 16 - - 17 FUSED B(+) (PUMP) A921 12RD/DB 18 - 19 FUSED B(+) A931 20RD/WT 20 - 21 GROUND Z971 16BK 22 RAD FAN RELAY CONTROL N112 20DB/OR Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6286 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C2 Color : LT. GRAY # of pins : 14 Pin Description Circuit 1 IGNITION SWITCH OUTPUT (UNLOCK-RUN-START) F901 20PK/RD 2 STARTER CONTROL T752 20DG/OR 3-4 FUEL PUMP CONTROL K31 20DB/BK 4 FUEL PUMP CONTROL K31 20BR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6287 5 FRONT WIPER PARK SWITCH SENSE W7 20BR/DB 6 GROUND Z924 20BK/LB 7 CAN C BUS (+) D265 20WT/BK 8-9-10 IGNITION SWITCH OUTPUT (UNLOCK-RUN-START) F901 20PK/RD 11 HOOD AJAR SWITCH SENSE G70 20VT/LB 12 - 13 GROUND Z925 20BK/YL 14 CAN C BUS (-) D264 20DB/WT Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6288 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C3 Color : BROWN # of pins : 16 Pin Description Circuit 1 CAN C BUS (+) D65 20WT/BK 2 DIAGNOSTIC CAN C (+) D72 20WT/TN 3 CAN B BUS (+) D55 20WT/OR 4 LEFT REAR TURN SIGNAL L63 20DG/RD 5-- Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6289 6 RIGHT REAR TURN SIGNAL L62 20WT/YL 7 STOP LAMP SWITCH OUTPUT L53 20DG/WT 8 PARK LAMP CONTROL OUTPUT L217 20WT/VT 9 CAN C BUS (-) D64 20WT/LB 10 DIAGNOSTIC CAN C (-) D71 20WT/DB 11 CAN B BUS (-) D54 20WT/PK 12 IGNITION SWITCH OUTPUT (START) F961 20PK/LB 13 STOP LAMP CONTROL OUTPUT L55 20WT/OR 14 - 15 RIGHT REAR WHEEL SPEED SENSOR SIGNAL B1 20YL/DB 16 RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY B2 20DG/TN Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6290 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C4 Color : BLACK # of pins : 10 Pin Description Circuit 1 LEFT TURN SIGNAL L61 20WT/RD 2 RIGHT TURN SIGNAL L60 20WT/TN 3 RIGHT HIGH BEAM OUTPUT L34 20WT/GY 4 LEFT LOW BEAM OUTPUT L43 20WT/DB 5-- Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6291 6-7-8 AAT SIGNAL G31 20VT/LG 9 AAT RETURN G931 20VT/DB 10 - Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6292 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C5 Color : BLUE # of pins : 14 Pin Description Circuit 1 HEADLAMP SWITCH OUTPUT L70 20WT/GY 2 RIGHT TURN SIGNAL (OUT) L160 20WT/TN 3 RIGHT LOW BEAM OUTPUT L44 20VT/RD 4 LEFT HIGH BEAM OUTPUT L33 20WT/PK 5 LEFT TURN SIGNAL (OUT) L161 20WT/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6293 6 HEADLAMP SWITCH OUTPUT L7 20WT/VT 6 HEADLAMP SWITCH OUTPUT L7 20WT/YL 7 A/C PRESSURE SENSOR SUPPLY C818 20LB/TN 8 BACKUP LAMP SWITCH SIGNAL T22 20YL/VT 9 HEADLAMP LEVEL SENSOR SIGNAL L131 20WT/LG 10 HEADLAMP LEVEL SENSOR SIGNAL L132 20LG/WT 11 - 12 A/C PRESSURE SENSOR SIGNAL C18 20LB/BR 13 A/C PRESSURE SENSOR GROUND C918 20BK/LB 14 IGNITION SWITCH OUTPUT (START) F962 20PK/BK Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6294 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C6 Color : LT. GRAY # of pins : 13 Pin Description Circuit 1-2-3-4-5 REAR WIPER MOTOR CONTROL W13 20BR/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6295 6-7-8-9-10 - 11 - 12 REAR FOG LAMP CONTROL OUTPUT L239 20WT/DG 13 - Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6296 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C7 Color : LT. GRAY # of pins : 22 Pin Description Circuit 1-2 FUSED B(+) A923 18RD/WT 2 FUSED B(+) A923 20RD/WT 3 FUSED B(+) A924 20DG/WT 4 FUSED B(+) A952 20RD/OR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6297 5 FUSED IGNITION SWITCH OUTPUT (RUN-START) F200 20PK/LB 6 FUSED B(+) A100 18RD/VT 7 FUSED IGNITION SWITCH OUTPUT (RUN) F100 20DG/YL 8-9 FUSED B(+) A933 20RD/LG 10 - 11 FUEL PUMP CONTROL OUTPUT N1 16DB/OR 12 - 13 FUSED B(+) (I.O.D.) A417 20RD/DG 14 - 15 FUSED B(+) (I.O.D.) A418 20RD/BK 16 FUSED B(+) (I.O.D.) A412 20RD/DB 17 FUSED B(+) A16 12RD/BR 18 DOOR LOCK POWER-FUSED B(+) A932 18RD/BR 19 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F996 20PK/YL 20 - 21 IGNITION SWITCH OUTPUT (RUN-ACC) F981 14PK/BR 22 FUSED B(+) A999 18RD/PK Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6298 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C8 Color : BLACK # of pins : 22 Pin Description Circuit 1 BLOWER MOTOR CONTROL C7 12DB/PK 2 FUSED B(+) A927 16RD/GY 3 FUSED B(+) (I.O.D.) A415 20RD/TN 4 FUSED B(+) (I.O.D.) A414 20RD/DG 5 FUSED B(+) (I.O.D.) A416 18RD Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6299 6 FUSED B(+) (I.O.D.) A420 18WT/RD 7 FUSED B(+) A14 12RD/YL 8 FUSED IGNITION SWITCH OUTPUT (RUN) F937 18PK/YL 9 FUSED REAR WINDOW DEFOGGER CONTROL OUTPUT C16 20DB/GY 10 - 11 BACKUP LAMP SWITCH OUTPUT L1 20WT/LG 12 FUSED IGNITION SWITCH OUTPUT (RUN) F929 20PK/RD 13 FUSED B(+) (I.O.D.) A411 20RD/LG 14 FUSED B(+) (I.O.D.) A419 18RD/DG 15 - 16 - - 17 REAR WINDOW DEFOGGER CONTROL OUTPUT C515 12LB/OR 18 FUSED B(+) (I.O.D.) A413 18RD/LB 19 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 20 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F985 18PK/YL 21 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F986 20PK/BK 22 MAIN RELAY OUTPUT K542 12BR/WT Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6300 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C9 Color : # of pins : 1 Pin Description Circuit 1 B(+) A0 6RD Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6301 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6302 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6303 Power Distribution Module: Diagrams Module-Inverter Component ID: 157 Component : MODULE-INVERTER Connector: Name : MODULE-INVERTER Color : # of pins : 9 Qualifier : (EXCEPT EXPORT) Pin Description Circuit 1 FUSED B(+) A999 16RD/PK 2-3 110 VOLT AC LINE 1 P801 18LG/PK 4 GROUND Z940 14BK/LG 5 INVERTER ENABLE SWITCH SIGNAL P805 18LG/DB 6-- 7-8 110 VOLT AC COMMON P809 18LG/LB 9-Component Location - 24 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6304 Component Location - 26 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6305 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Totally Integrated Power Module Power Distribution Module: Description and Operation Totally Integrated Power Module Description DESCRIPTION All of the electrical current distributed throughout this vehicle is directed through the standard equipment Totally Integrated Power Module (TIPM) (1). The molded plastic TIPM housing is located in the left front corner of the engine compartment, just behind the air cleaner housing and the battery. The TIPM housing has a molded plastic cover. The TIPM cover is easily removed for service access and has a convenient fuse and relay layout label affixed to the inside surface of the cover to ensure proper component identification. The TIPM housing is secured to the left inner fender well an indexing pin and one screw. All of the TIPM outputs are through the integral engine compartment wire harness. Operation OPERATION All of the current from the generator cable connection goes to the battery through a 10 gauge fusible link that is secured with a nut to the positive battery terminal at the starter. Internal connection of all the Totally Integrated Power Module (TIPM) circuits is accomplished by an intricate network of hard wiring and bus bars. Refer to Wiring Diagrams for complete circuit diagrams. The fusible link, fuses and relays are available for service replacement. The TIPM unit cannot be repaired and is only serviced as a unit with the engine compartment wire harness. If the TIPM is inoperative or damaged, the engine compartment wire harness assembly must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Totally Integrated Power Module > Page 6308 Power Distribution Module: Description and Operation Module-Inverter Description DESCRIPTION The inverter module is located in the instrument panel. The A/C outlet is mounted in the center console. The inverter module provides A/C power for user accessories. The inverter converts the 12 Volt DC from the battery system to a 110 Volt AC output. Operation OPERATION The AC power outlet receives 12 volts from the Totally Integrated Power Module (TIPM) and passes it as an enable signal to the inverter module. The inverter module also receives 12 volts via the TIPM and inverts this to a 110 volt AC output. The enable signal received from the power outlet enables the inverter to convert the received voltage and pass it to the power outlet to power external devices. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Page 6309 Power Distribution Module: Testing and Inspection Inverter Module For complete circuit diagrams, refer to the appropriate wiring information. WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Totally Integrated Power Module Power Distribution Module: Service and Repair Totally Integrated Power Module Removal REMOVAL The TIPM (TIPM) is serviced as a unit with the engine compartment wire harness. If any internal circuit of the TIPM or the TIPM housing is faulty or damaged, the entire TIPM and engine compartment wire harness unit must be replaced. Refer to Wiring Diagrams for the locations of the affected connectors. 1. Open hood. 2. Disconnect and isolate the battery negative cable. 3. Disconnect each of the engine compartment wire harness connectors. 4. Remove the fasteners that secure each of the engine compartment wire harness ground eyelets to the vehicle body and chassis components. 5. Disengage each of the retainers that secure the engine compartment wire harness to the vehicle body and chassis components. 6. Disengage and remove the TIPM housing from its mounting bracket. 7. Remove the TIPM and the engine compartment wire harness from the engine compartment as a unit. Installation INSTALLATION The Totally Integrated Power Module (TIPM) is serviced as a unit with the engine compartment wire harness. If any internal circuit of the TIPM or the TIPM housing is faulty or damaged, the entire TIPM and engine compartment wire harness unit must be replaced. NOTE: If the Totally Integrated Power Module (TIPM) is being replaced with a new unit, be certain to transfer each of the fuses and relays from the old TIPM to the proper cavities of the new TIPM. Refer to Wiring Diagrams for the proper TIPM cavity assignments. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Totally Integrated Power Module > Page 6312 1. Position the TIPM in the engine compartment. 2. Align the TIPM on its mounting bracket and install. 3. Route the engine compartment wire harness from the TIPM through the engine compartment, engaging each of the harness retainers to the mounting provisions in the vehicle body and chassis components. Refer to Wiring Diagrams for the harness routing and retainer locations. 4. Install and tighten the fasteners that secure each of the engine compartment wire harness ground eyelets to the vehicle body and chassis components. Refer to Wiring Diagrams for the ground eyelet locations. 5. Reconnect each of the engine compartment wire harness connectors. Refer to Wiring Diagrams for the locations of the affected connectors. 6. Torque nut retaining positive battery cable at TIPM to 96 - 141 Nm (85 - 130 in. lbs.). 7. Reconnect the battery negative cable. 8. Close hood. 9. Verify vehicle and system operation. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Totally Integrated Power Module > Page 6313 Power Distribution Module: Service and Repair Module-Inverter Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. 1. Disconnect and isolate the negative battery cable. 2. Remove the shift bezel. 3. Remove the center bezel from the instrument panel. 4. Remove the fasteners from the mounting brackets of the inverter module. 5. Disconnect the electrical connectors and remove the inverter module. Installation INSTALLATION 1. Connect the electrical connectors to the inverter module. 2. Install the fasteners to the mounting brackets. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Totally Integrated Power Module > Page 6314 3. Install the center bezel to the instrument panel. 4. Install the shift bezel. 5. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Removal Power Distribution Relay: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove cover from Totally Integrated Power module (TIPM). 3. Using special tool C-4817 (1), grip the relay (2) by the sides and pull upward with an even effort. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Removal > Page 6319 Power Distribution Relay: Service and Repair Installation INSTALLATION 1. Align relay (2) with Totally Integrated Power Module (TIPM) and press into position. 2. Install cover to TIPM. 3. Connect battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Interrupt Connector/Switch > Component Information > Description and Operation > Description Power Interrupt Connector/Switch: Description and Operation Description DESCRIPTION All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is disconnected within the Totally Integrated Power Module (TIPM) when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the TIPM as part of the preparation procedures performed just prior to new vehicle delivery. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Interrupt Connector/Switch > Component Information > Description and Operation > Description > Page 6324 Power Interrupt Connector/Switch: Description and Operation Operation OPERATION The term ignition-off draw identifies a normal condition where power is being drained from the battery with the ignition switch in the Off position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the Off position, including the clock. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is disconnected from Totally Integrated Power Module (TIPM) fuse cavities 7 and 8 in a preset fuse holder. when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse serves no useful purpose to the dealer technician in the service or diagnosis of any vehicle system or condition, other than the same purpose as that of any other standard circuit protection device. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Interrupt Connector/Switch > Component Information > Service and Repair > Removal Power Interrupt Connector/Switch: Service and Repair Removal REMOVAL NOTE: When removing or installing the IOD fuse, it is important that the ignition switch be in the Off position. Failure to place the ignition switch in the Off position can cause the radio display to become scrambled when the IOD fuse is installed. Removing and installing the IOD fuse again with the ignition switch in the Off position will usually correct the scrambled radio display condition. 1. Turn the ignition switch to the Off position. 2. Remove the cover from the Totally Integrated Power Module (TIPM). 3. Remove fuse 7/8 from the TIPM. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Interrupt Connector/Switch > Component Information > Service and Repair > Removal > Page 6327 Power Interrupt Connector/Switch: Service and Repair Installation INSTALLATION CAUTION: It is extremely important that the Ignition Off Draw (IOD) fuses are fully seated into the Totally Integrated Power Module (TIPM) fuse cavities. Failure to install the fuses correctly could result in erratic electrical systems behavior. 1. Remove TIPM cover. 2. Insert fuse 7/8 into the TIPM. Push fuses down until they are fully seated in the TIPM cavities. 3. Install the cover to the TIPM. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Service and Repair > Removal Mini ISO Relay: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove cover from Totally Integrated Power module (TIPM). 3. Using special tool C-4817 (1), grip the relay (2) by the sides and pull upward with an even effort. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Service and Repair > Removal > Page 6333 Mini ISO Relay: Service and Repair Installation INSTALLATION 1. Align relay (2) with Totally Integrated Power Module (TIPM) and press into position. 2. Install cover to TIPM. 3. Connect battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Recalls: > G42 > Jan > 08 > Campaign - TIPM Software Update for Antitheft System Technical Service Bulletin # G42 Date: 080101 Campaign - TIPM Software Update for Antitheft System January 2008 Distributor/Dealer Service Instructions for: Customer Satisfaction Notice G42 TIPM Re-Configure, Anti-Theft System Models 2007 2008 (JS/PM/MK) Sebring, Avenger, Caliber, Compass and Patriot vehicles (International Markets Only) NOTE: This customer satisfaction notice applies only to the above vehicles built at the Sterling Heights Assembly Plant through July 25, 2007 (MDH 0725XX) and the Belvidere Assembly Plant through July 23, 2007 (MDH 0723XX). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this customer satisfaction notice. IMPORTANT: Some of the involved vehicles may be in distributor/dealer used vehicle inventory. Distributors/Dealers should complete this recall service on these vehicles before retail delivery. Distributors/Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Totally Integrated Power Module (TIPM) vehicles may be configured incorrectly preventing the Anti-Theft Security System from operating properly. Repair The Totally Integrated Power Module (TIPM) must be Re-Configured. Special Tools These existing special tools are required to perform this repair. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Recalls: > G42 > Jan > 08 > Campaign - TIPM Software Update for Antitheft System > Page 6342 Use the labor operation number and time allowance shown. Distributor/ Dealer Notification and Vehicle List Regional offices will receive an electronic list of involved vehicles. The Vehicle List is arranged by Distributor/Dealer code and in Vehicle Identification Number (VIN) sequence. The lists are for Distributor/Dealer reference in arranging for service of involved vehicles. Owner Notification and Service Scheduling All involved vehicle owners should be notified of the service requirement by their Distributor/Dealer. Owners are requested to schedule appointments for this service. A sample copy of the owner notification letter is included. Vehicle Lists, Global Recall System, VIP and Distributor/Dealer Follow up All involved vehicles have been entered into the Global Recall System (GRS) and Vehicle Information Plus (VIP) for Distributor/Dealer inquiry as needed. GRS provides involved Distributors/Dealers with an updated VIN list of their incomplete vehicles. Completed vehicles are removed from GRS within several days of repair claim submission. Distributors/Dealers must perform this repair on all unsold vehicles before retail delivery. Distributors/Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Additional Information If you have any questions or need assistance in completing this action, please contact your International Service and Parts Manager. Global Service & Parts - International Chrysler LLC Service Procedure NOTE: Use StarSCAN(R) to perform this Customer Satisfaction Notice. This procedure must be performed using software release 8.02 or higher. Re-Configure the TIPM using StarSCAN(R) 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN(R) Ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN® vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN(R). 5. Re-Configure the TIPM as Follows: a. With the StarSCAN(R) on the "Home" screen, select "ECU View". b. Select "TIPMCGW Central Gateway" in the list of modules. c. Select "Misc Functions". Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Recalls: > G42 > Jan > 08 > Campaign - TIPM Software Update for Antitheft System > Page 6343 d. Select "Restore Vehicle Configuration". e. Press "Start". f. Follow the prompts listed on the StarSCAN(R). g. When prompted, Enter the full 17 digit VIN found on the VIN plate. NOTE: Assure the correct VIN is input into the StarSCAN(R). h. Select "Next". NOTE: The StarSCAN(R) must be connected to the dealer network drop. i. Follow the prompts listed on the StarSCAN(R). 6. Check and clear any Diagnostic Trouble Codes (DTC's) that may have been set. 7. Turn the ignition key to the "OFF" position and remove the StarSCAN(R) unit, StarSCAN(R) cable, and battery charger from the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition Power Distribution Module: Customer Interest Antitheft System - Engine No Crank/No Start Condition NUMBER: 08-007-08 REV. A GROUP: Electrical DATE: July 04,2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-007-08, DATED MARCH 04, 2008. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. DO NOT ORDER PART NUMBER 05026070AP UNTIL JULY 21, 2008. ALL OTHER PART NUMBERS ARE AVAILABLE NOW. SUBJECT: No Engine Crank Or No Engine Start Due To Electronic Lockup Of The WCM / SKREEM OVERVIEW: This bulletin involves the replacement of the Wireless Control Module (WCM), and if equipped, the replacement of the Electric Steering Column Lock (ELV). The WCM is also referred to as the Sentry Key Remote Entry Module (SKREEM). MODELS: 2007 - 2008 (DR/DH/D1/DC/DM) Ram Truck (1500/2500/3500/4500/5500) 2007 - 2008 (JK) Wrangler 2007 - 2008 (J1) Sebring (China) 2007 - 2008 (JS) Avenger/Sebring 2007 - 2008 (KA) Nitro 2008 (KK) Liberty/Cherokee 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber 2006 - 2008 (PT) Chrysler PT Cruiser NOTE: This bulletin applies to vehicles built on or before May 05, 2008 (MDH 0505XX). SYMPTOM/CONDITION: The customer will experience a no engine crank AND a no engine start condition. Also, the remote keyless entry (RKE) system will not operate. This condition may be due to an electrostatic discharge (ESD) from the ignition key into the Wireless Control Module (WCM), causing the WCM to electronically lockup. This condition may occur more frequently in dry and/or cold weather conditions where a sufficient electrostatic charge is more easily produced. This condition is corrected by the replacement of the WCM. DIAGNOSIS: 1. With the condition present (i.e. the vehicle in the no crank / no start condition), connect the StarSCAN(R) scan tool to the vehicle. 2. Turn the ignition switch to the "ON position, and power up the StarSCAN(R). 3. If the WCM is electronically locked up, the StarSCAN(R) will display the WCM as being "off bus". 4. If the no crank / no start condition is present, and the WCM is "off bus", then reset the WCM by temporarily removing the IOD fuse (with the key out of the ignition switch), wait for 10 seconds and then reinstall the IOD fuse. 5. With the IOD fuse reset having been performed, verify that the vehicle will now crank, start, and run. 6. If the condition is temporarily corrected by performing the above steps, and if the part number of the WCM is earlier than the part number of the WCM listed in the part reference table in the Service Bulletin Parts Required Section below, then perform the Repair Procedure. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 6349 PARTS REQUIRED: NOTE: The part numbers listed in the following part reference table are to be used as A GUIDE to help determine if the WCM, that is currently in the vehicle, may require replacement. If it is determined that the WCM requires replacement, then ALWAYS REFER TO THE PARTS MANUAL to determine the correct WCM for the specific vehicle in question. In some earlier model years, the WCM may rule (supersede) to one of the part numbers listed in the table. ALWAYS REFER TO THE PARTS MANUAL (not the part reference table) to determine the correct part number ruling (supercedence / substitution). MAKE CERTAIN THAT THE CORRECT WCM IS ORDERED THE FIRST TIME FOR THE SPECIFIC VEHICLE IN QUESTION. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 6350 REPAIR PROCEDURE: NOTE: If the vehicle (a JS model vehicle in certain International markets) is equipped with an Electric Steering Column Lock (ELV), then the WCM and the ELV must be replaced. Replace the WCM and then the ELV. Next program the WCM and at least one (1) ignition key BEFORE programming the ELV. IMPORTANT: Not following this repair process correctly will cause the new ELV to fail. NOTE: Insert the ignition key into the ignition lock cylinder. This will move the shaft lock module locking bolt to the unlocked position. LEAVE the key in the lock cylinder while the shaft lock module is being removed. 1. If vehicle is equipped with a Steering Shaft Lock Module (JS - Avenger I Stratus - some International Markets), then the Shaft Lock Module will require replacement. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Security Information > Module, Shaft Lock > Removal and Installation. NOTE: The shaft lock module cannot be removed from the steering column while the locking bolt is in the locked position without irreversibly damaging the column. Before attempting service, the ignition key must have been inserted into the ignition lock cylinder. Then rotate the steering wheel from side to side. If the steering wheel can be rotated, the locking bolt is in the unlocked position. Leave the key in the ignition lock cylinder until shaft lock module removal has been completed. If the steering wheel cannot be rotated, test and repair the wiring circuits between the module and the ignition switch as required. If no problem is found in these circuits, the module has failed with the locking bolt in the locked position and both the module and the steering column must be replaced with new units. 2. Replace the WCM/SKREEM. Refer to TechCONNECT for detailed service information. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Service Information > Module, Sentry Key Remote Entry > Removal and Installation. NOTE: Obtain the vehicle PIN number prior to programming WCM/SKREEM or ELV. NOTE: If during the following steps the PIN number is properly entered but is rejected, then reenter the PIN number again until it is accepted. 3. After both the WCM/SKREEM and the ELV (if equipped) have been replaced, Program the WCM/SKREEM as follows: a. Turn the ignition key to the ON position, (Engine Off) b. Connect the scan tool (StarSCAN(R)) to the data link connector and turn the ignition to the RUN position, (engine off). c. Select "ECU View." d. Scroll down and select "WCM" in the list of modules. e. Select "Misc. Functions." f. Scroll to "WCM Replaced." g. Press "Start". h. Press "Next". i. Select "Show Keyboard". j. Enter the vehicle PIN number. k. Select "Next". l. Verify PIN is correct. m. Select "Next". n. Follow on-screen prompts to complete WCM function programing for Tire Pressure Monitoring (TPM) and so on. 0. Turn the ignition key to the OFF position. Wait 30 seconds. p. Turn the ignition key to the ON position, (Engine Off) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 6351 q. Select "ECU View". r. Scroll down and select "WCM" in the list of modules. s. Select "Misc. Functions." t. Select "Program Ign. Keys" and follow on-screen prompts. u. Select "Complete". v. Verify ignition key will start vehicle and the Remote Keyless Entry (RKE) functions operate. CAUTION: If the vehicle is equipped with a Shaft Lock Module (used in some International Markets on JS model vehicles), then at least one (1 ignition key must have been programmed to the new WCM BEFORE the new Shaft Lock Module is "married" to the new WCM. 4. Is the vehicle equipped with Steering Shaft Lock Module (ELV)? a. Yes >> Proceed to Step # 5. b. No >>Repair is complete. 5. Program the ELV as follows; a. Select "ECU View". b. Scroll down and select "WCM" in the list of modules. c. Select "Misc. Functions". d. Scroll to "ELV Replaced." e. Press "Start". f. When complete, verify steering shaft lock mechanism is operating. Remove and insert key from the ignition lock cylinder and listen for solenoid "click at lower end of column. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 6352 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition Power Distribution Module: All Technical Service Bulletins Antitheft System - Engine No Crank/No Start Condition NUMBER: 08-007-08 REV. A GROUP: Electrical DATE: July 04,2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-007-08, DATED MARCH 04, 2008. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. DO NOT ORDER PART NUMBER 05026070AP UNTIL JULY 21, 2008. ALL OTHER PART NUMBERS ARE AVAILABLE NOW. SUBJECT: No Engine Crank Or No Engine Start Due To Electronic Lockup Of The WCM / SKREEM OVERVIEW: This bulletin involves the replacement of the Wireless Control Module (WCM), and if equipped, the replacement of the Electric Steering Column Lock (ELV). The WCM is also referred to as the Sentry Key Remote Entry Module (SKREEM). MODELS: 2007 - 2008 (DR/DH/D1/DC/DM) Ram Truck (1500/2500/3500/4500/5500) 2007 - 2008 (JK) Wrangler 2007 - 2008 (J1) Sebring (China) 2007 - 2008 (JS) Avenger/Sebring 2007 - 2008 (KA) Nitro 2008 (KK) Liberty/Cherokee 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber 2006 - 2008 (PT) Chrysler PT Cruiser NOTE: This bulletin applies to vehicles built on or before May 05, 2008 (MDH 0505XX). SYMPTOM/CONDITION: The customer will experience a no engine crank AND a no engine start condition. Also, the remote keyless entry (RKE) system will not operate. This condition may be due to an electrostatic discharge (ESD) from the ignition key into the Wireless Control Module (WCM), causing the WCM to electronically lockup. This condition may occur more frequently in dry and/or cold weather conditions where a sufficient electrostatic charge is more easily produced. This condition is corrected by the replacement of the WCM. DIAGNOSIS: 1. With the condition present (i.e. the vehicle in the no crank / no start condition), connect the StarSCAN(R) scan tool to the vehicle. 2. Turn the ignition switch to the "ON position, and power up the StarSCAN(R). 3. If the WCM is electronically locked up, the StarSCAN(R) will display the WCM as being "off bus". 4. If the no crank / no start condition is present, and the WCM is "off bus", then reset the WCM by temporarily removing the IOD fuse (with the key out of the ignition switch), wait for 10 seconds and then reinstall the IOD fuse. 5. With the IOD fuse reset having been performed, verify that the vehicle will now crank, start, and run. 6. If the condition is temporarily corrected by performing the above steps, and if the part number of the WCM is earlier than the part number of the WCM listed in the part reference table in the Service Bulletin Parts Required Section below, then perform the Repair Procedure. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 6358 PARTS REQUIRED: NOTE: The part numbers listed in the following part reference table are to be used as A GUIDE to help determine if the WCM, that is currently in the vehicle, may require replacement. If it is determined that the WCM requires replacement, then ALWAYS REFER TO THE PARTS MANUAL to determine the correct WCM for the specific vehicle in question. In some earlier model years, the WCM may rule (supersede) to one of the part numbers listed in the table. ALWAYS REFER TO THE PARTS MANUAL (not the part reference table) to determine the correct part number ruling (supercedence / substitution). MAKE CERTAIN THAT THE CORRECT WCM IS ORDERED THE FIRST TIME FOR THE SPECIFIC VEHICLE IN QUESTION. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 6359 REPAIR PROCEDURE: NOTE: If the vehicle (a JS model vehicle in certain International markets) is equipped with an Electric Steering Column Lock (ELV), then the WCM and the ELV must be replaced. Replace the WCM and then the ELV. Next program the WCM and at least one (1) ignition key BEFORE programming the ELV. IMPORTANT: Not following this repair process correctly will cause the new ELV to fail. NOTE: Insert the ignition key into the ignition lock cylinder. This will move the shaft lock module locking bolt to the unlocked position. LEAVE the key in the lock cylinder while the shaft lock module is being removed. 1. If vehicle is equipped with a Steering Shaft Lock Module (JS - Avenger I Stratus - some International Markets), then the Shaft Lock Module will require replacement. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Security Information > Module, Shaft Lock > Removal and Installation. NOTE: The shaft lock module cannot be removed from the steering column while the locking bolt is in the locked position without irreversibly damaging the column. Before attempting service, the ignition key must have been inserted into the ignition lock cylinder. Then rotate the steering wheel from side to side. If the steering wheel can be rotated, the locking bolt is in the unlocked position. Leave the key in the ignition lock cylinder until shaft lock module removal has been completed. If the steering wheel cannot be rotated, test and repair the wiring circuits between the module and the ignition switch as required. If no problem is found in these circuits, the module has failed with the locking bolt in the locked position and both the module and the steering column must be replaced with new units. 2. Replace the WCM/SKREEM. Refer to TechCONNECT for detailed service information. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Service Information > Module, Sentry Key Remote Entry > Removal and Installation. NOTE: Obtain the vehicle PIN number prior to programming WCM/SKREEM or ELV. NOTE: If during the following steps the PIN number is properly entered but is rejected, then reenter the PIN number again until it is accepted. 3. After both the WCM/SKREEM and the ELV (if equipped) have been replaced, Program the WCM/SKREEM as follows: a. Turn the ignition key to the ON position, (Engine Off) b. Connect the scan tool (StarSCAN(R)) to the data link connector and turn the ignition to the RUN position, (engine off). c. Select "ECU View." d. Scroll down and select "WCM" in the list of modules. e. Select "Misc. Functions." f. Scroll to "WCM Replaced." g. Press "Start". h. Press "Next". i. Select "Show Keyboard". j. Enter the vehicle PIN number. k. Select "Next". l. Verify PIN is correct. m. Select "Next". n. Follow on-screen prompts to complete WCM function programing for Tire Pressure Monitoring (TPM) and so on. 0. Turn the ignition key to the OFF position. Wait 30 seconds. p. Turn the ignition key to the ON position, (Engine Off) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 6360 q. Select "ECU View". r. Scroll down and select "WCM" in the list of modules. s. Select "Misc. Functions." t. Select "Program Ign. Keys" and follow on-screen prompts. u. Select "Complete". v. Verify ignition key will start vehicle and the Remote Keyless Entry (RKE) functions operate. CAUTION: If the vehicle is equipped with a Shaft Lock Module (used in some International Markets on JS model vehicles), then at least one (1 ignition key must have been programmed to the new WCM BEFORE the new Shaft Lock Module is "married" to the new WCM. 4. Is the vehicle equipped with Steering Shaft Lock Module (ELV)? a. Yes >> Proceed to Step # 5. b. No >>Repair is complete. 5. Program the ELV as follows; a. Select "ECU View". b. Scroll down and select "WCM" in the list of modules. c. Select "Misc. Functions". d. Scroll to "ELV Replaced." e. Press "Start". f. When complete, verify steering shaft lock mechanism is operating. Remove and insert key from the ignition lock cylinder and listen for solenoid "click at lower end of column. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 6361 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > G42 > Jan > 08 > Campaign - TIPM Software Update for Antitheft System Technical Service Bulletin # G42 Date: 080101 Campaign - TIPM Software Update for Antitheft System January 2008 Distributor/Dealer Service Instructions for: Customer Satisfaction Notice G42 TIPM Re-Configure, Anti-Theft System Models 2007 2008 (JS/PM/MK) Sebring, Avenger, Caliber, Compass and Patriot vehicles (International Markets Only) NOTE: This customer satisfaction notice applies only to the above vehicles built at the Sterling Heights Assembly Plant through July 25, 2007 (MDH 0725XX) and the Belvidere Assembly Plant through July 23, 2007 (MDH 0723XX). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this customer satisfaction notice. IMPORTANT: Some of the involved vehicles may be in distributor/dealer used vehicle inventory. Distributors/Dealers should complete this recall service on these vehicles before retail delivery. Distributors/Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Totally Integrated Power Module (TIPM) vehicles may be configured incorrectly preventing the Anti-Theft Security System from operating properly. Repair The Totally Integrated Power Module (TIPM) must be Re-Configured. Special Tools These existing special tools are required to perform this repair. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > G42 > Jan > 08 > Campaign - TIPM Software Update for Antitheft System > Page 6366 Use the labor operation number and time allowance shown. Distributor/ Dealer Notification and Vehicle List Regional offices will receive an electronic list of involved vehicles. The Vehicle List is arranged by Distributor/Dealer code and in Vehicle Identification Number (VIN) sequence. The lists are for Distributor/Dealer reference in arranging for service of involved vehicles. Owner Notification and Service Scheduling All involved vehicle owners should be notified of the service requirement by their Distributor/Dealer. Owners are requested to schedule appointments for this service. A sample copy of the owner notification letter is included. Vehicle Lists, Global Recall System, VIP and Distributor/Dealer Follow up All involved vehicles have been entered into the Global Recall System (GRS) and Vehicle Information Plus (VIP) for Distributor/Dealer inquiry as needed. GRS provides involved Distributors/Dealers with an updated VIN list of their incomplete vehicles. Completed vehicles are removed from GRS within several days of repair claim submission. Distributors/Dealers must perform this repair on all unsold vehicles before retail delivery. Distributors/Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Additional Information If you have any questions or need assistance in completing this action, please contact your International Service and Parts Manager. Global Service & Parts - International Chrysler LLC Service Procedure NOTE: Use StarSCAN(R) to perform this Customer Satisfaction Notice. This procedure must be performed using software release 8.02 or higher. Re-Configure the TIPM using StarSCAN(R) 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN(R) Ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN® vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN(R). 5. Re-Configure the TIPM as Follows: a. With the StarSCAN(R) on the "Home" screen, select "ECU View". b. Select "TIPMCGW Central Gateway" in the list of modules. c. Select "Misc Functions". Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > G42 > Jan > 08 > Campaign - TIPM Software Update for Antitheft System > Page 6367 d. Select "Restore Vehicle Configuration". e. Press "Start". f. Follow the prompts listed on the StarSCAN(R). g. When prompted, Enter the full 17 digit VIN found on the VIN plate. NOTE: Assure the correct VIN is input into the StarSCAN(R). h. Select "Next". NOTE: The StarSCAN(R) must be connected to the dealer network drop. i. Follow the prompts listed on the StarSCAN(R). 6. Check and clear any Diagnostic Trouble Codes (DTC's) that may have been set. 7. Turn the ignition key to the "OFF" position and remove the StarSCAN(R) unit, StarSCAN(R) cable, and battery charger from the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition Power Distribution Module: All Technical Service Bulletins Antitheft System - Engine No Crank/No Start Condition NUMBER: 08-007-08 REV. A GROUP: Electrical DATE: July 04,2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-007-08, DATED MARCH 04, 2008. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. DO NOT ORDER PART NUMBER 05026070AP UNTIL JULY 21, 2008. ALL OTHER PART NUMBERS ARE AVAILABLE NOW. SUBJECT: No Engine Crank Or No Engine Start Due To Electronic Lockup Of The WCM / SKREEM OVERVIEW: This bulletin involves the replacement of the Wireless Control Module (WCM), and if equipped, the replacement of the Electric Steering Column Lock (ELV). The WCM is also referred to as the Sentry Key Remote Entry Module (SKREEM). MODELS: 2007 - 2008 (DR/DH/D1/DC/DM) Ram Truck (1500/2500/3500/4500/5500) 2007 - 2008 (JK) Wrangler 2007 - 2008 (J1) Sebring (China) 2007 - 2008 (JS) Avenger/Sebring 2007 - 2008 (KA) Nitro 2008 (KK) Liberty/Cherokee 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber 2006 - 2008 (PT) Chrysler PT Cruiser NOTE: This bulletin applies to vehicles built on or before May 05, 2008 (MDH 0505XX). SYMPTOM/CONDITION: The customer will experience a no engine crank AND a no engine start condition. Also, the remote keyless entry (RKE) system will not operate. This condition may be due to an electrostatic discharge (ESD) from the ignition key into the Wireless Control Module (WCM), causing the WCM to electronically lockup. This condition may occur more frequently in dry and/or cold weather conditions where a sufficient electrostatic charge is more easily produced. This condition is corrected by the replacement of the WCM. DIAGNOSIS: 1. With the condition present (i.e. the vehicle in the no crank / no start condition), connect the StarSCAN(R) scan tool to the vehicle. 2. Turn the ignition switch to the "ON position, and power up the StarSCAN(R). 3. If the WCM is electronically locked up, the StarSCAN(R) will display the WCM as being "off bus". 4. If the no crank / no start condition is present, and the WCM is "off bus", then reset the WCM by temporarily removing the IOD fuse (with the key out of the ignition switch), wait for 10 seconds and then reinstall the IOD fuse. 5. With the IOD fuse reset having been performed, verify that the vehicle will now crank, start, and run. 6. If the condition is temporarily corrected by performing the above steps, and if the part number of the WCM is earlier than the part number of the WCM listed in the part reference table in the Service Bulletin Parts Required Section below, then perform the Repair Procedure. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 6373 PARTS REQUIRED: NOTE: The part numbers listed in the following part reference table are to be used as A GUIDE to help determine if the WCM, that is currently in the vehicle, may require replacement. If it is determined that the WCM requires replacement, then ALWAYS REFER TO THE PARTS MANUAL to determine the correct WCM for the specific vehicle in question. In some earlier model years, the WCM may rule (supersede) to one of the part numbers listed in the table. ALWAYS REFER TO THE PARTS MANUAL (not the part reference table) to determine the correct part number ruling (supercedence / substitution). MAKE CERTAIN THAT THE CORRECT WCM IS ORDERED THE FIRST TIME FOR THE SPECIFIC VEHICLE IN QUESTION. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 6374 REPAIR PROCEDURE: NOTE: If the vehicle (a JS model vehicle in certain International markets) is equipped with an Electric Steering Column Lock (ELV), then the WCM and the ELV must be replaced. Replace the WCM and then the ELV. Next program the WCM and at least one (1) ignition key BEFORE programming the ELV. IMPORTANT: Not following this repair process correctly will cause the new ELV to fail. NOTE: Insert the ignition key into the ignition lock cylinder. This will move the shaft lock module locking bolt to the unlocked position. LEAVE the key in the lock cylinder while the shaft lock module is being removed. 1. If vehicle is equipped with a Steering Shaft Lock Module (JS - Avenger I Stratus - some International Markets), then the Shaft Lock Module will require replacement. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Security Information > Module, Shaft Lock > Removal and Installation. NOTE: The shaft lock module cannot be removed from the steering column while the locking bolt is in the locked position without irreversibly damaging the column. Before attempting service, the ignition key must have been inserted into the ignition lock cylinder. Then rotate the steering wheel from side to side. If the steering wheel can be rotated, the locking bolt is in the unlocked position. Leave the key in the ignition lock cylinder until shaft lock module removal has been completed. If the steering wheel cannot be rotated, test and repair the wiring circuits between the module and the ignition switch as required. If no problem is found in these circuits, the module has failed with the locking bolt in the locked position and both the module and the steering column must be replaced with new units. 2. Replace the WCM/SKREEM. Refer to TechCONNECT for detailed service information. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Service Information > Module, Sentry Key Remote Entry > Removal and Installation. NOTE: Obtain the vehicle PIN number prior to programming WCM/SKREEM or ELV. NOTE: If during the following steps the PIN number is properly entered but is rejected, then reenter the PIN number again until it is accepted. 3. After both the WCM/SKREEM and the ELV (if equipped) have been replaced, Program the WCM/SKREEM as follows: a. Turn the ignition key to the ON position, (Engine Off) b. Connect the scan tool (StarSCAN(R)) to the data link connector and turn the ignition to the RUN position, (engine off). c. Select "ECU View." d. Scroll down and select "WCM" in the list of modules. e. Select "Misc. Functions." f. Scroll to "WCM Replaced." g. Press "Start". h. Press "Next". i. Select "Show Keyboard". j. Enter the vehicle PIN number. k. Select "Next". l. Verify PIN is correct. m. Select "Next". n. Follow on-screen prompts to complete WCM function programing for Tire Pressure Monitoring (TPM) and so on. 0. Turn the ignition key to the OFF position. Wait 30 seconds. p. Turn the ignition key to the ON position, (Engine Off) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 6375 q. Select "ECU View". r. Scroll down and select "WCM" in the list of modules. s. Select "Misc. Functions." t. Select "Program Ign. Keys" and follow on-screen prompts. u. Select "Complete". v. Verify ignition key will start vehicle and the Remote Keyless Entry (RKE) functions operate. CAUTION: If the vehicle is equipped with a Shaft Lock Module (used in some International Markets on JS model vehicles), then at least one (1 ignition key must have been programmed to the new WCM BEFORE the new Shaft Lock Module is "married" to the new WCM. 4. Is the vehicle equipped with Steering Shaft Lock Module (ELV)? a. Yes >> Proceed to Step # 5. b. No >>Repair is complete. 5. Program the ELV as follows; a. Select "ECU View". b. Scroll down and select "WCM" in the list of modules. c. Select "Misc. Functions". d. Scroll to "ELV Replaced." e. Press "Start". f. When complete, verify steering shaft lock mechanism is operating. Remove and insert key from the ignition lock cylinder and listen for solenoid "click at lower end of column. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 6376 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Distribution Module: > G42 > Jan > 08 > Campaign - TIPM Software Update for Antitheft System Technical Service Bulletin # G42 Date: 080101 Campaign - TIPM Software Update for Antitheft System January 2008 Distributor/Dealer Service Instructions for: Customer Satisfaction Notice G42 TIPM Re-Configure, Anti-Theft System Models 2007 2008 (JS/PM/MK) Sebring, Avenger, Caliber, Compass and Patriot vehicles (International Markets Only) NOTE: This customer satisfaction notice applies only to the above vehicles built at the Sterling Heights Assembly Plant through July 25, 2007 (MDH 0725XX) and the Belvidere Assembly Plant through July 23, 2007 (MDH 0723XX). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this customer satisfaction notice. IMPORTANT: Some of the involved vehicles may be in distributor/dealer used vehicle inventory. Distributors/Dealers should complete this recall service on these vehicles before retail delivery. Distributors/Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Totally Integrated Power Module (TIPM) vehicles may be configured incorrectly preventing the Anti-Theft Security System from operating properly. Repair The Totally Integrated Power Module (TIPM) must be Re-Configured. Special Tools These existing special tools are required to perform this repair. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Distribution Module: > G42 > Jan > 08 > Campaign - TIPM Software Update for Antitheft System > Page 6382 Use the labor operation number and time allowance shown. Distributor/ Dealer Notification and Vehicle List Regional offices will receive an electronic list of involved vehicles. The Vehicle List is arranged by Distributor/Dealer code and in Vehicle Identification Number (VIN) sequence. The lists are for Distributor/Dealer reference in arranging for service of involved vehicles. Owner Notification and Service Scheduling All involved vehicle owners should be notified of the service requirement by their Distributor/Dealer. Owners are requested to schedule appointments for this service. A sample copy of the owner notification letter is included. Vehicle Lists, Global Recall System, VIP and Distributor/Dealer Follow up All involved vehicles have been entered into the Global Recall System (GRS) and Vehicle Information Plus (VIP) for Distributor/Dealer inquiry as needed. GRS provides involved Distributors/Dealers with an updated VIN list of their incomplete vehicles. Completed vehicles are removed from GRS within several days of repair claim submission. Distributors/Dealers must perform this repair on all unsold vehicles before retail delivery. Distributors/Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Additional Information If you have any questions or need assistance in completing this action, please contact your International Service and Parts Manager. Global Service & Parts - International Chrysler LLC Service Procedure NOTE: Use StarSCAN(R) to perform this Customer Satisfaction Notice. This procedure must be performed using software release 8.02 or higher. Re-Configure the TIPM using StarSCAN(R) 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN(R) Ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN® vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN(R). 5. Re-Configure the TIPM as Follows: a. With the StarSCAN(R) on the "Home" screen, select "ECU View". b. Select "TIPMCGW Central Gateway" in the list of modules. c. Select "Misc Functions". Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Distribution Module: > G42 > Jan > 08 > Campaign - TIPM Software Update for Antitheft System > Page 6383 d. Select "Restore Vehicle Configuration". e. Press "Start". f. Follow the prompts listed on the StarSCAN(R). g. When prompted, Enter the full 17 digit VIN found on the VIN plate. NOTE: Assure the correct VIN is input into the StarSCAN(R). h. Select "Next". NOTE: The StarSCAN(R) must be connected to the dealer network drop. i. Follow the prompts listed on the StarSCAN(R). 6. Check and clear any Diagnostic Trouble Codes (DTC's) that may have been set. 7. Turn the ignition key to the "OFF" position and remove the StarSCAN(R) unit, StarSCAN(R) cable, and battery charger from the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead Power Distribution Module: Locations Module-Electronic Overhead Component ID: 148 Component : MODULE-ELECTRONIC OVERHEAD Connector: Name : MODULE-ELECTRONIC OVERHEAD C1 Color : BLACK # of pins : 3 A READING/RAIL LAMPS DRIVER M27 20YL/LB B GROUND Z936 20BK/LB C COURTESY LAMPS DRIVER M24 20YL/WT Component Location - 43 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6386 Connector: Name : MODULE-ELECTRONIC OVERHEAD C2 Color : BLACK # of pins : 4 A SUNROOF VENT SWITCH SENSE Q4 20OR/YL B SUNROOF SWITCH SUPPLY Q6 20OR/LG C SUNROOF OPEN SWITCH SENSE Q3 20OR/TN D SUNROOF CLOSE SWITCH SENSE Q5 20OR/LB Component Location - 43 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6387 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6388 Power Distribution Module: Locations Module-Totally Integrated Power Component ID: 163 Component : MODULE-TOTALLY INTEGRATED POWER Connector: Name : MODULE-TOTALLY INTEGRATED POWER C1 Color : BLACK # of pins : 13 Pin Description Circuit 1 REAR WASHER PUMP MOTOR CONTROL W20 20BR/YL 2 FRONT WASHER PUMP MOTOR CONTROL W10 20BR/TN 3 IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4-5-6 CABIN HEATER RELAY 2 CONTROL K232 20BR/LB 7 CABIN HEATER RELAY 1 CONTROL K132 20DB/LB 8-9-10 - 11 - 12 BRAKE FLUID LEVEL SWITCH SENSE B20 20DG/RD 13 GROUND Z924 20BK/LB Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6389 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6390 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C10 Color : LT. GRAY # of pins : 8 Pin Description Circuit 1-2-3 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 4-5 FUSED MAIN RELAY OUTPUT F343 18DB/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6391 6 FUSED MAIN RELAY OUTPUT F344 18DB/LB 7-8 STARTER CONTROL OUTPUT T750 16YL/GY Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6392 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C11 Color : GREEN # of pins : 22 Pin Description Circuit 1 FUSED MAIN RELAY OUTPUT F342 14BR/DG 2-3-4 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 5 FRONT FOG LAMP CONTROL OUTPUT L89 20WT/YL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6393 6 FRONT FOG LAMP CONTROL OUTPUT L90 20WT/OR 7 LOW/HIGH RAD FAN RELAY CONTROL N201 20DB/LG 8 HORN CONTROL OUTPUT X22 20GY/LB 9 HORN CONTROL OUTPUT X21 20GY/YL 10 FRONT WIPER HIGH SPEED CONTROL OUTPUT W4 16BR/LB 11 FUSED B(+) A935 20RD/LB 12 FRONT WIPER LOW SPEED CONTROL OUTPUT W3 16BR/WT 13 FUSED IGNITION SWITCH OUTPUT (RUN) F936 20PK/YL 14 FUSED B(+) (VALVE) A922 14RD/BK 15 - 16 - - 17 FUSED B(+) (PUMP) A921 12RD/DB 18 - 19 FUSED B(+) A931 20RD/WT 20 - 21 GROUND Z971 16BK 22 RAD FAN RELAY CONTROL N112 20DB/OR Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6394 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C2 Color : LT. GRAY # of pins : 14 Pin Description Circuit 1 IGNITION SWITCH OUTPUT (UNLOCK-RUN-START) F901 20PK/RD 2 STARTER CONTROL T752 20DG/OR 3-4 FUEL PUMP CONTROL K31 20DB/BK 4 FUEL PUMP CONTROL K31 20BR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6395 5 FRONT WIPER PARK SWITCH SENSE W7 20BR/DB 6 GROUND Z924 20BK/LB 7 CAN C BUS (+) D265 20WT/BK 8-9-10 IGNITION SWITCH OUTPUT (UNLOCK-RUN-START) F901 20PK/RD 11 HOOD AJAR SWITCH SENSE G70 20VT/LB 12 - 13 GROUND Z925 20BK/YL 14 CAN C BUS (-) D264 20DB/WT Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6396 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C3 Color : BROWN # of pins : 16 Pin Description Circuit 1 CAN C BUS (+) D65 20WT/BK 2 DIAGNOSTIC CAN C (+) D72 20WT/TN 3 CAN B BUS (+) D55 20WT/OR 4 LEFT REAR TURN SIGNAL L63 20DG/RD 5-- Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6397 6 RIGHT REAR TURN SIGNAL L62 20WT/YL 7 STOP LAMP SWITCH OUTPUT L53 20DG/WT 8 PARK LAMP CONTROL OUTPUT L217 20WT/VT 9 CAN C BUS (-) D64 20WT/LB 10 DIAGNOSTIC CAN C (-) D71 20WT/DB 11 CAN B BUS (-) D54 20WT/PK 12 IGNITION SWITCH OUTPUT (START) F961 20PK/LB 13 STOP LAMP CONTROL OUTPUT L55 20WT/OR 14 - 15 RIGHT REAR WHEEL SPEED SENSOR SIGNAL B1 20YL/DB 16 RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY B2 20DG/TN Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6398 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C4 Color : BLACK # of pins : 10 Pin Description Circuit 1 LEFT TURN SIGNAL L61 20WT/RD 2 RIGHT TURN SIGNAL L60 20WT/TN 3 RIGHT HIGH BEAM OUTPUT L34 20WT/GY 4 LEFT LOW BEAM OUTPUT L43 20WT/DB 5-- Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6399 6-7-8 AAT SIGNAL G31 20VT/LG 9 AAT RETURN G931 20VT/DB 10 - Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6400 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C5 Color : BLUE # of pins : 14 Pin Description Circuit 1 HEADLAMP SWITCH OUTPUT L70 20WT/GY 2 RIGHT TURN SIGNAL (OUT) L160 20WT/TN 3 RIGHT LOW BEAM OUTPUT L44 20VT/RD 4 LEFT HIGH BEAM OUTPUT L33 20WT/PK 5 LEFT TURN SIGNAL (OUT) L161 20WT/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6401 6 HEADLAMP SWITCH OUTPUT L7 20WT/VT 6 HEADLAMP SWITCH OUTPUT L7 20WT/YL 7 A/C PRESSURE SENSOR SUPPLY C818 20LB/TN 8 BACKUP LAMP SWITCH SIGNAL T22 20YL/VT 9 HEADLAMP LEVEL SENSOR SIGNAL L131 20WT/LG 10 HEADLAMP LEVEL SENSOR SIGNAL L132 20LG/WT 11 - 12 A/C PRESSURE SENSOR SIGNAL C18 20LB/BR 13 A/C PRESSURE SENSOR GROUND C918 20BK/LB 14 IGNITION SWITCH OUTPUT (START) F962 20PK/BK Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6402 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C6 Color : LT. GRAY # of pins : 13 Pin Description Circuit 1-2-3-4-5 REAR WIPER MOTOR CONTROL W13 20BR/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6403 6-7-8-9-10 - 11 - 12 REAR FOG LAMP CONTROL OUTPUT L239 20WT/DG 13 - Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6404 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C7 Color : LT. GRAY # of pins : 22 Pin Description Circuit 1-2 FUSED B(+) A923 18RD/WT 2 FUSED B(+) A923 20RD/WT 3 FUSED B(+) A924 20DG/WT 4 FUSED B(+) A952 20RD/OR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6405 5 FUSED IGNITION SWITCH OUTPUT (RUN-START) F200 20PK/LB 6 FUSED B(+) A100 18RD/VT 7 FUSED IGNITION SWITCH OUTPUT (RUN) F100 20DG/YL 8-9 FUSED B(+) A933 20RD/LG 10 - 11 FUEL PUMP CONTROL OUTPUT N1 16DB/OR 12 - 13 FUSED B(+) (I.O.D.) A417 20RD/DG 14 - 15 FUSED B(+) (I.O.D.) A418 20RD/BK 16 FUSED B(+) (I.O.D.) A412 20RD/DB 17 FUSED B(+) A16 12RD/BR 18 DOOR LOCK POWER-FUSED B(+) A932 18RD/BR 19 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F996 20PK/YL 20 - 21 IGNITION SWITCH OUTPUT (RUN-ACC) F981 14PK/BR 22 FUSED B(+) A999 18RD/PK Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6406 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C8 Color : BLACK # of pins : 22 Pin Description Circuit 1 BLOWER MOTOR CONTROL C7 12DB/PK 2 FUSED B(+) A927 16RD/GY 3 FUSED B(+) (I.O.D.) A415 20RD/TN 4 FUSED B(+) (I.O.D.) A414 20RD/DG 5 FUSED B(+) (I.O.D.) A416 18RD Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6407 6 FUSED B(+) (I.O.D.) A420 18WT/RD 7 FUSED B(+) A14 12RD/YL 8 FUSED IGNITION SWITCH OUTPUT (RUN) F937 18PK/YL 9 FUSED REAR WINDOW DEFOGGER CONTROL OUTPUT C16 20DB/GY 10 - 11 BACKUP LAMP SWITCH OUTPUT L1 20WT/LG 12 FUSED IGNITION SWITCH OUTPUT (RUN) F929 20PK/RD 13 FUSED B(+) (I.O.D.) A411 20RD/LG 14 FUSED B(+) (I.O.D.) A419 18RD/DG 15 - 16 - - 17 REAR WINDOW DEFOGGER CONTROL OUTPUT C515 12LB/OR 18 FUSED B(+) (I.O.D.) A413 18RD/LB 19 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 20 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F985 18PK/YL 21 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F986 20PK/BK 22 MAIN RELAY OUTPUT K542 12BR/WT Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6408 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C9 Color : # of pins : 1 Pin Description Circuit 1 B(+) A0 6RD Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6409 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6410 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6411 Power Distribution Module: Locations Module-Inverter Component ID: 157 Component : MODULE-INVERTER Connector: Name : MODULE-INVERTER Color : # of pins : 9 Qualifier : (EXCEPT EXPORT) Pin Description Circuit 1 FUSED B(+) A999 16RD/PK 2-3 110 VOLT AC LINE 1 P801 18LG/PK 4 GROUND Z940 14BK/LG 5 INVERTER ENABLE SWITCH SIGNAL P805 18LG/DB 6-- 7-8 110 VOLT AC COMMON P809 18LG/LB 9-Component Location - 24 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6412 Component Location - 26 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 6413 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead Power Distribution Module: Diagrams Module-Electronic Overhead Component ID: 148 Component : MODULE-ELECTRONIC OVERHEAD Connector: Name : MODULE-ELECTRONIC OVERHEAD C1 Color : BLACK # of pins : 3 A READING/RAIL LAMPS DRIVER M27 20YL/LB B GROUND Z936 20BK/LB C COURTESY LAMPS DRIVER M24 20YL/WT Component Location - 43 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6416 Connector: Name : MODULE-ELECTRONIC OVERHEAD C2 Color : BLACK # of pins : 4 A SUNROOF VENT SWITCH SENSE Q4 20OR/YL B SUNROOF SWITCH SUPPLY Q6 20OR/LG C SUNROOF OPEN SWITCH SENSE Q3 20OR/TN D SUNROOF CLOSE SWITCH SENSE Q5 20OR/LB Component Location - 43 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6417 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6418 Power Distribution Module: Diagrams Module-Totally Integrated Power Component ID: 163 Component : MODULE-TOTALLY INTEGRATED POWER Connector: Name : MODULE-TOTALLY INTEGRATED POWER C1 Color : BLACK # of pins : 13 Pin Description Circuit 1 REAR WASHER PUMP MOTOR CONTROL W20 20BR/YL 2 FRONT WASHER PUMP MOTOR CONTROL W10 20BR/TN 3 IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4-5-6 CABIN HEATER RELAY 2 CONTROL K232 20BR/LB 7 CABIN HEATER RELAY 1 CONTROL K132 20DB/LB 8-9-10 - 11 - 12 BRAKE FLUID LEVEL SWITCH SENSE B20 20DG/RD 13 GROUND Z924 20BK/LB Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6419 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6420 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C10 Color : LT. GRAY # of pins : 8 Pin Description Circuit 1-2-3 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 4-5 FUSED MAIN RELAY OUTPUT F343 18DB/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6421 6 FUSED MAIN RELAY OUTPUT F344 18DB/LB 7-8 STARTER CONTROL OUTPUT T750 16YL/GY Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6422 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C11 Color : GREEN # of pins : 22 Pin Description Circuit 1 FUSED MAIN RELAY OUTPUT F342 14BR/DG 2-3-4 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 5 FRONT FOG LAMP CONTROL OUTPUT L89 20WT/YL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6423 6 FRONT FOG LAMP CONTROL OUTPUT L90 20WT/OR 7 LOW/HIGH RAD FAN RELAY CONTROL N201 20DB/LG 8 HORN CONTROL OUTPUT X22 20GY/LB 9 HORN CONTROL OUTPUT X21 20GY/YL 10 FRONT WIPER HIGH SPEED CONTROL OUTPUT W4 16BR/LB 11 FUSED B(+) A935 20RD/LB 12 FRONT WIPER LOW SPEED CONTROL OUTPUT W3 16BR/WT 13 FUSED IGNITION SWITCH OUTPUT (RUN) F936 20PK/YL 14 FUSED B(+) (VALVE) A922 14RD/BK 15 - 16 - - 17 FUSED B(+) (PUMP) A921 12RD/DB 18 - 19 FUSED B(+) A931 20RD/WT 20 - 21 GROUND Z971 16BK 22 RAD FAN RELAY CONTROL N112 20DB/OR Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6424 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C2 Color : LT. GRAY # of pins : 14 Pin Description Circuit 1 IGNITION SWITCH OUTPUT (UNLOCK-RUN-START) F901 20PK/RD 2 STARTER CONTROL T752 20DG/OR 3-4 FUEL PUMP CONTROL K31 20DB/BK 4 FUEL PUMP CONTROL K31 20BR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6425 5 FRONT WIPER PARK SWITCH SENSE W7 20BR/DB 6 GROUND Z924 20BK/LB 7 CAN C BUS (+) D265 20WT/BK 8-9-10 IGNITION SWITCH OUTPUT (UNLOCK-RUN-START) F901 20PK/RD 11 HOOD AJAR SWITCH SENSE G70 20VT/LB 12 - 13 GROUND Z925 20BK/YL 14 CAN C BUS (-) D264 20DB/WT Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6426 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C3 Color : BROWN # of pins : 16 Pin Description Circuit 1 CAN C BUS (+) D65 20WT/BK 2 DIAGNOSTIC CAN C (+) D72 20WT/TN 3 CAN B BUS (+) D55 20WT/OR 4 LEFT REAR TURN SIGNAL L63 20DG/RD 5-- Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6427 6 RIGHT REAR TURN SIGNAL L62 20WT/YL 7 STOP LAMP SWITCH OUTPUT L53 20DG/WT 8 PARK LAMP CONTROL OUTPUT L217 20WT/VT 9 CAN C BUS (-) D64 20WT/LB 10 DIAGNOSTIC CAN C (-) D71 20WT/DB 11 CAN B BUS (-) D54 20WT/PK 12 IGNITION SWITCH OUTPUT (START) F961 20PK/LB 13 STOP LAMP CONTROL OUTPUT L55 20WT/OR 14 - 15 RIGHT REAR WHEEL SPEED SENSOR SIGNAL B1 20YL/DB 16 RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY B2 20DG/TN Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6428 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C4 Color : BLACK # of pins : 10 Pin Description Circuit 1 LEFT TURN SIGNAL L61 20WT/RD 2 RIGHT TURN SIGNAL L60 20WT/TN 3 RIGHT HIGH BEAM OUTPUT L34 20WT/GY 4 LEFT LOW BEAM OUTPUT L43 20WT/DB 5-- Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6429 6-7-8 AAT SIGNAL G31 20VT/LG 9 AAT RETURN G931 20VT/DB 10 - Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6430 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C5 Color : BLUE # of pins : 14 Pin Description Circuit 1 HEADLAMP SWITCH OUTPUT L70 20WT/GY 2 RIGHT TURN SIGNAL (OUT) L160 20WT/TN 3 RIGHT LOW BEAM OUTPUT L44 20VT/RD 4 LEFT HIGH BEAM OUTPUT L33 20WT/PK 5 LEFT TURN SIGNAL (OUT) L161 20WT/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6431 6 HEADLAMP SWITCH OUTPUT L7 20WT/VT 6 HEADLAMP SWITCH OUTPUT L7 20WT/YL 7 A/C PRESSURE SENSOR SUPPLY C818 20LB/TN 8 BACKUP LAMP SWITCH SIGNAL T22 20YL/VT 9 HEADLAMP LEVEL SENSOR SIGNAL L131 20WT/LG 10 HEADLAMP LEVEL SENSOR SIGNAL L132 20LG/WT 11 - 12 A/C PRESSURE SENSOR SIGNAL C18 20LB/BR 13 A/C PRESSURE SENSOR GROUND C918 20BK/LB 14 IGNITION SWITCH OUTPUT (START) F962 20PK/BK Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6432 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C6 Color : LT. GRAY # of pins : 13 Pin Description Circuit 1-2-3-4-5 REAR WIPER MOTOR CONTROL W13 20BR/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6433 6-7-8-9-10 - 11 - 12 REAR FOG LAMP CONTROL OUTPUT L239 20WT/DG 13 - Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6434 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C7 Color : LT. GRAY # of pins : 22 Pin Description Circuit 1-2 FUSED B(+) A923 18RD/WT 2 FUSED B(+) A923 20RD/WT 3 FUSED B(+) A924 20DG/WT 4 FUSED B(+) A952 20RD/OR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6435 5 FUSED IGNITION SWITCH OUTPUT (RUN-START) F200 20PK/LB 6 FUSED B(+) A100 18RD/VT 7 FUSED IGNITION SWITCH OUTPUT (RUN) F100 20DG/YL 8-9 FUSED B(+) A933 20RD/LG 10 - 11 FUEL PUMP CONTROL OUTPUT N1 16DB/OR 12 - 13 FUSED B(+) (I.O.D.) A417 20RD/DG 14 - 15 FUSED B(+) (I.O.D.) A418 20RD/BK 16 FUSED B(+) (I.O.D.) A412 20RD/DB 17 FUSED B(+) A16 12RD/BR 18 DOOR LOCK POWER-FUSED B(+) A932 18RD/BR 19 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F996 20PK/YL 20 - 21 IGNITION SWITCH OUTPUT (RUN-ACC) F981 14PK/BR 22 FUSED B(+) A999 18RD/PK Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6436 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C8 Color : BLACK # of pins : 22 Pin Description Circuit 1 BLOWER MOTOR CONTROL C7 12DB/PK 2 FUSED B(+) A927 16RD/GY 3 FUSED B(+) (I.O.D.) A415 20RD/TN 4 FUSED B(+) (I.O.D.) A414 20RD/DG 5 FUSED B(+) (I.O.D.) A416 18RD Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6437 6 FUSED B(+) (I.O.D.) A420 18WT/RD 7 FUSED B(+) A14 12RD/YL 8 FUSED IGNITION SWITCH OUTPUT (RUN) F937 18PK/YL 9 FUSED REAR WINDOW DEFOGGER CONTROL OUTPUT C16 20DB/GY 10 - 11 BACKUP LAMP SWITCH OUTPUT L1 20WT/LG 12 FUSED IGNITION SWITCH OUTPUT (RUN) F929 20PK/RD 13 FUSED B(+) (I.O.D.) A411 20RD/LG 14 FUSED B(+) (I.O.D.) A419 18RD/DG 15 - 16 - - 17 REAR WINDOW DEFOGGER CONTROL OUTPUT C515 12LB/OR 18 FUSED B(+) (I.O.D.) A413 18RD/LB 19 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 20 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F985 18PK/YL 21 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F986 20PK/BK 22 MAIN RELAY OUTPUT K542 12BR/WT Component Location - 8 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6438 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C9 Color : # of pins : 1 Pin Description Circuit 1 B(+) A0 6RD Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6439 Component Location - 9 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6440 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6441 Power Distribution Module: Diagrams Module-Inverter Component ID: 157 Component : MODULE-INVERTER Connector: Name : MODULE-INVERTER Color : # of pins : 9 Qualifier : (EXCEPT EXPORT) Pin Description Circuit 1 FUSED B(+) A999 16RD/PK 2-3 110 VOLT AC LINE 1 P801 18LG/PK 4 GROUND Z940 14BK/LG 5 INVERTER ENABLE SWITCH SIGNAL P805 18LG/DB 6-- 7-8 110 VOLT AC COMMON P809 18LG/LB 9-Component Location - 24 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6442 Component Location - 26 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 6443 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Totally Integrated Power Module Power Distribution Module: Description and Operation Totally Integrated Power Module Description DESCRIPTION All of the electrical current distributed throughout this vehicle is directed through the standard equipment Totally Integrated Power Module (TIPM) (1). The molded plastic TIPM housing is located in the left front corner of the engine compartment, just behind the air cleaner housing and the battery. The TIPM housing has a molded plastic cover. The TIPM cover is easily removed for service access and has a convenient fuse and relay layout label affixed to the inside surface of the cover to ensure proper component identification. The TIPM housing is secured to the left inner fender well an indexing pin and one screw. All of the TIPM outputs are through the integral engine compartment wire harness. Operation OPERATION All of the current from the generator cable connection goes to the battery through a 10 gauge fusible link that is secured with a nut to the positive battery terminal at the starter. Internal connection of all the Totally Integrated Power Module (TIPM) circuits is accomplished by an intricate network of hard wiring and bus bars. Refer to Wiring Diagrams for complete circuit diagrams. The fusible link, fuses and relays are available for service replacement. The TIPM unit cannot be repaired and is only serviced as a unit with the engine compartment wire harness. If the TIPM is inoperative or damaged, the engine compartment wire harness assembly must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Totally Integrated Power Module > Page 6446 Power Distribution Module: Description and Operation Module-Inverter Description DESCRIPTION The inverter module is located in the instrument panel. The A/C outlet is mounted in the center console. The inverter module provides A/C power for user accessories. The inverter converts the 12 Volt DC from the battery system to a 110 Volt AC output. Operation OPERATION The AC power outlet receives 12 volts from the Totally Integrated Power Module (TIPM) and passes it as an enable signal to the inverter module. The inverter module also receives 12 volts via the TIPM and inverts this to a 110 volt AC output. The enable signal received from the power outlet enables the inverter to convert the received voltage and pass it to the power outlet to power external devices. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Page 6447 Power Distribution Module: Testing and Inspection Inverter Module For complete circuit diagrams, refer to the appropriate wiring information. WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Totally Integrated Power Module Power Distribution Module: Service and Repair Totally Integrated Power Module Removal REMOVAL The TIPM (TIPM) is serviced as a unit with the engine compartment wire harness. If any internal circuit of the TIPM or the TIPM housing is faulty or damaged, the entire TIPM and engine compartment wire harness unit must be replaced. Refer to Wiring Diagrams for the locations of the affected connectors. 1. Open hood. 2. Disconnect and isolate the battery negative cable. 3. Disconnect each of the engine compartment wire harness connectors. 4. Remove the fasteners that secure each of the engine compartment wire harness ground eyelets to the vehicle body and chassis components. 5. Disengage each of the retainers that secure the engine compartment wire harness to the vehicle body and chassis components. 6. Disengage and remove the TIPM housing from its mounting bracket. 7. Remove the TIPM and the engine compartment wire harness from the engine compartment as a unit. Installation INSTALLATION The Totally Integrated Power Module (TIPM) is serviced as a unit with the engine compartment wire harness. If any internal circuit of the TIPM or the TIPM housing is faulty or damaged, the entire TIPM and engine compartment wire harness unit must be replaced. NOTE: If the Totally Integrated Power Module (TIPM) is being replaced with a new unit, be certain to transfer each of the fuses and relays from the old TIPM to the proper cavities of the new TIPM. Refer to Wiring Diagrams for the proper TIPM cavity assignments. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Totally Integrated Power Module > Page 6450 1. Position the TIPM in the engine compartment. 2. Align the TIPM on its mounting bracket and install. 3. Route the engine compartment wire harness from the TIPM through the engine compartment, engaging each of the harness retainers to the mounting provisions in the vehicle body and chassis components. Refer to Wiring Diagrams for the harness routing and retainer locations. 4. Install and tighten the fasteners that secure each of the engine compartment wire harness ground eyelets to the vehicle body and chassis components. Refer to Wiring Diagrams for the ground eyelet locations. 5. Reconnect each of the engine compartment wire harness connectors. Refer to Wiring Diagrams for the locations of the affected connectors. 6. Torque nut retaining positive battery cable at TIPM to 96 - 141 Nm (85 - 130 in. lbs.). 7. Reconnect the battery negative cable. 8. Close hood. 9. Verify vehicle and system operation. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Totally Integrated Power Module > Page 6451 Power Distribution Module: Service and Repair Module-Inverter Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. 1. Disconnect and isolate the negative battery cable. 2. Remove the shift bezel. 3. Remove the center bezel from the instrument panel. 4. Remove the fasteners from the mounting brackets of the inverter module. 5. Disconnect the electrical connectors and remove the inverter module. Installation INSTALLATION 1. Connect the electrical connectors to the inverter module. 2. Install the fasteners to the mounting brackets. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Totally Integrated Power Module > Page 6452 3. Install the center bezel to the instrument panel. 4. Install the shift bezel. 5. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Removal Power Distribution Relay: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove cover from Totally Integrated Power module (TIPM). 3. Using special tool C-4817 (1), grip the relay (2) by the sides and pull upward with an even effort. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Removal > Page 6457 Power Distribution Relay: Service and Repair Installation INSTALLATION 1. Align relay (2) with Totally Integrated Power Module (TIPM) and press into position. 2. Install cover to TIPM. 3. Connect battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6461 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6462 Relay Box: Application and ID Fuse/Relay Block Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6466 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6467 Relay Box: Application and ID Fuse/Relay Block Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Power Interrupt Connector/Switch > Component Information > Description and Operation > Description Power Interrupt Connector/Switch: Description and Operation Description DESCRIPTION All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is disconnected within the Totally Integrated Power Module (TIPM) when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the TIPM as part of the preparation procedures performed just prior to new vehicle delivery. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Power Interrupt Connector/Switch > Component Information > Description and Operation > Description > Page 6473 Power Interrupt Connector/Switch: Description and Operation Operation OPERATION The term ignition-off draw identifies a normal condition where power is being drained from the battery with the ignition switch in the Off position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the Off position, including the clock. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is disconnected from Totally Integrated Power Module (TIPM) fuse cavities 7 and 8 in a preset fuse holder. when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse serves no useful purpose to the dealer technician in the service or diagnosis of any vehicle system or condition, other than the same purpose as that of any other standard circuit protection device. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Power Interrupt Connector/Switch > Component Information > Service and Repair > Removal Power Interrupt Connector/Switch: Service and Repair Removal REMOVAL NOTE: When removing or installing the IOD fuse, it is important that the ignition switch be in the Off position. Failure to place the ignition switch in the Off position can cause the radio display to become scrambled when the IOD fuse is installed. Removing and installing the IOD fuse again with the ignition switch in the Off position will usually correct the scrambled radio display condition. 1. Turn the ignition switch to the Off position. 2. Remove the cover from the Totally Integrated Power Module (TIPM). 3. Remove fuse 7/8 from the TIPM. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Power Interrupt Connector/Switch > Component Information > Service and Repair > Removal > Page 6476 Power Interrupt Connector/Switch: Service and Repair Installation INSTALLATION CAUTION: It is extremely important that the Ignition Off Draw (IOD) fuses are fully seated into the Totally Integrated Power Module (TIPM) fuse cavities. Failure to install the fuses correctly could result in erratic electrical systems behavior. 1. Remove TIPM cover. 2. Insert fuse 7/8 into the TIPM. Push fuses down until they are fully seated in the TIPM cavities. 3. Install the cover to the TIPM. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Wheel Alignment Specifications Alignment: Specifications Wheel Alignment Specifications Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Wheel Alignment Specifications > Page 6482 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Wheel Alignment Specifications > Page 6483 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Wheel Alignment Specifications > Page 6484 Alignment: Specifications Curb Height Specifications CURB HEIGHT MEASUREMENT The wheel alignment is to be checked and all alignment adjustments made with the vehicle at its required curb height specification. Vehicle height is to be checked with the vehicle on a flat, level surface, preferably a vehicle alignment rack. The tires are to be inflated to the recommended pressure. All tires are to be the same size as standard equipment. Vehicle height is checked with the fuel tank full of fuel, and no passenger or luggage compartment load. Vehicle height is not adjustable. If the measurement is not within specifications, inspect the vehicle for bent or weak suspension components. Compare the parts tag on the suspect coil spring(s) to the parts book and the vehicle sales code, checking for a match. Once removed from the vehicle, compare the coil spring height to a correct new or known good coil spring. The heights should vary if the suspect spring is weak. NOTE: Prior to reading the curb height measurement, the front and rear of the vehicle must be jounced to settle the suspension. Induce jounce by pushing down on the center of the bumper (fascia), using care not to damage the vehicle, moving the vehicle up and down, gradually increasing the suspension travel with each stroke. Release the bumper at the bottom of each stroke, repeating this action several times. Perform this to both front and rear suspensions an equal amount of times. Measure curb height as follows: 1. Jounce the vehicle. Refer to above note. NOTE: On some vehicles it may be necessary to remove an engine belly pan in order to gain access to the lower control arm pivot bolt. 2. FRONT - On each side of the vehicle, measure the distance (2) from the lower control arm rear (vertical) pivot bolt head (1) to the floor or alignment rack/lift runway surface. It may be necessary to measure to the bottom of a straight edge (3), placed from lift runway to runway, to get an accurate measurement. 3. REAR - On each side of the vehicle, measure the distance (2) from the center of the outboard trailing arm-to-body mounting bolt (1) to the floor or Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Wheel Alignment Specifications > Page 6485 alignment rack/lift runway surface. 4. Compare the measurements to specifications listed in the following CURB HEIGHT SPECIFICATIONS chart. Maximum left-to-right differential is not to exceed 12.5 mm (0.5 in.). 5. If curb height is found to be out of specification and there is no sign of excessive body damage, curb height can be changed by replacing the applicable spring with a spring offering a different check load. Curb Height Specifications Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6486 Alignment: Description and Operation DESCRIPTION Vehicle wheel alignment is the positioning of all interrelated front and rear suspension angles. These angles affect the handling and steering of the vehicle when it is in motion. Proper wheel alignment is essential for efficient steering, good directional stability, and proper tire wear. The method of checking a vehicle's front and rear wheel alignment varies depending on the manufacturer and type of equipment used. The manufacturer's instructions should always be followed to ensure accuracy of the alignment, except when DaimlerChrysler Corporation's wheel alignment specifications differ. On this vehicle, the suspension angles that can be adjusted are as follows: Front - Camber (with cradle shift or service adjustment bolt package) - Caster (limited adjustment with cradle shift) - Toe Rear - Toe Check the wheel alignment and make all wheel alignment adjustments with the vehicle standing at its proper curb height specification. Curb height is the normal riding height of the vehicle. It is measured from a certain point on the vehicle to the ground or a designated area while the vehicle is sitting on a flat, level surface. Refer to Curb Height Measurement. Typical wheel alignment angles and measurements are described in the following paragraphs. CAMBER Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6487 Camber is the inward or outward tilt of the top of the tire and wheel assembly. Inward tilt (2) is known as negative camber. Outward tilt (1) is known as positive camber. Camber is measured in degrees of angle relative to a true vertical line. Camber is a tire wearing angle. - Excessive negative camber will cause tread wear at the inside of the tire. - Excessive positive camber will cause tread wear on the outside of the tire. CROSS CAMBER Cross camber is the difference between left and right camber. To achieve the cross camber reading, subtract the right side camber reading from the left. For example, if the left camber is -0.7° and the right camber is -0.5°, the cross camber would be -0.2° (-0.7 - (-0.5) = -0.7 + 0.5 = -0.2). CASTER Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6488 Caster is the forward or rearward tilt of the steering knuckle in reference to the position of the upper and lower ball joints. Caster is measured in degrees of angle relative to a true vertical center line. This line is viewed from the side of the tire and wheel assembly. - Forward tilt (upper ball joint ahead of lower) results in a negative caster angle. - Rearward tilt (upper ball joint trailing lower) results in a positive caster angle. Although caster does not affect tire wear, a caster imbalance between the two front wheels may cause the vehicle to lead to the side with the least positive caster. CROSS CASTER Cross caster is the difference between left and right caster. To achieve the cross caster reading, subtract the right side caster reading from the left. For example, if the left caster is 2.5° and the right caster is 2.7°, the cross caster would be -0.2° (2.5 - 2.7 = -0.2). TOE Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6489 Toe is the inward or outward angle of the wheels as viewed from above the vehicle. - Toe-in (1) is produced when the front edges of the wheels on the same axle are closer together than the rear edges. - Toe-out (2) is produced when the front edges of the wheels on the same axle are farther apart than the rear edges. Toe-in and toe-out can occur at the front wheels and the rear wheels. Toe is measured in degrees or inches. The measurement identifies the amount that the front of the wheels point inward (toe-in) or outward (toe-out). Toe is measured at the spindle height. Zero toe means the front and rear edges of the wheels on the same axle are equal distant. TOE-OUT ON TURNS Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6490 Toe-out on turns (1), sometimes referred to as Ackerman Steering, is the relative positioning of the front wheels while steering through a turn. This compensates for each front wheel's turning radius. As the vehicle encounters a turn, the outboard wheel must travel in a larger radius circle than the inboard wheel. The steering system is designed to make each wheel follow its particular radius circle. To accomplish this, the front wheels must progressively toe outward as the steering is turned from center. This eliminates tire scrubbing and undue tire wear when steering a vehicle through a turn. DYNAMIC TOE PATTERN Dynamic toe pattern is the inward and outward toe movement of the front and rear tires through the suspension's jounce and rebound travel. As the vehicle's suspension moves up and down, the toe pattern varies. Toe pattern is critical in controlling the directional stability of the vehicle while in motion. Front and rear dynamic toe pattern is preset by the factory at the time the vehicle is assembled. It is not necessary to check or adjust front or rear dynamic toe pattern when doing a normal wheel alignment. The only time dynamic toe pattern needs to be checked or adjusted is if the frame of the vehicle has been damaged. STEERING AXIS INCLINATION (S.A.I.) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6491 Steering axis inclination (1) is the angle between a true vertical line starting at the center of the tire at the road contact point and a line drawn through the center of the upper ball joint (or strut) and the lower ball joint. S.A.I. is built into the vehicle and is not an adjustable angle. If S.A.I. is not within specifications, a bent or damaged suspension component may be the cause. INCLUDED ANGLE (I.A.) Included angle (3) is the sum of the S.A.I. angle (1) plus or minus the camber angle (2), depending on whether or not the wheel has positive or negative camber. If camber is positive, add the camber angle to the S.A.I angle. If camber is negative, subtract the camber angle from the S.A.I. angle. Included angle is not adjustable, but can be used to diagnose a frame misalignment or bent suspension component (spindle, strut). THRUST ANGLE Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6492 Thrust angle is the averaged direction the rear wheels are pointing in relation to the vehicle's center line. The presence of negative or positive thrust angle causes the rear tires to track improperly to the left or right of the front tires (dog tracking). - Negative thrust angle means the rear tires are tracking to the left of the front tires. - Positive thrust angle means the rear tires are tracking to the right of the front tires. Improper tracking can cause undue tire wear, a lead or pull and a crooked steering wheel. Excessive thrust angle can usually be corrected by adjusting the rear wheel toe so that each wheel has one-half of the total toe measurement. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6493 Alignment: Testing and Inspection SUSPENSION AND STEERING Suspension And Steering (Part 1) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6494 Suspension And Steering (Part 2) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6495 Suspension And Steering (Part 3) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel Alignment Alignment: Service and Repair Wheel Alignment WHEEL ALIGNMENT PRE-WHEEL ALIGNMENT INSPECTION Before any attempt is made to change or correct the wheel alignment, the following inspection and necessary corrections must be made to the vehicle to ensure proper alignment. 1. Verify the fuel tank is full of fuel. If the fuel tank is not full, the reduction in weight will affect the curb height of the vehicle and the alignment specifications. 2. The passenger and luggage compartments of the vehicle should be free of any load that is not factory equipment. 3. Check the tires on the vehicle. The tires are to be inflated to the recommended air pressure. All tires must be the same size and in good condition with approximately the same tread wear. 4. Check the front tire and wheel assemblies for excessive radial runout. 5. Inspect all suspension component fasteners for looseness and proper torque. 6. Inspect the lower front ball joints and all steering linkage for looseness and any sign of wear or damage. 7. Inspect the rubber bushings on all the suspension components for signs of wear or deterioration. If any bushings show signs of wear or deterioration, they should be replaced prior to aligning the vehicle. 8. Check vehicle curb height to verify it is within specifications. WHEEL ALIGNMENT SETUP 1. Position the vehicle on an alignment rack. 2. Install all required alignment equipment on the vehicle, per the alignment equipment manufacturer's instructions. On this vehicle, a four-wheel alignment is recommended. NOTE: Prior to reading the vehicle's alignment readouts, the front and rear of vehicle should be jounced. Induce jounce (rear first, then front) by grasping the center of the bumper and jouncing each end of vehicle an equal number of times. The bumper should always be released when vehicle is at the bottom of the jounce cycle. 3. Read the vehicle's current front and rear alignment settings. Compare the vehicle's current alignment settings to the vehicle specifications for camber, caster and toe-in. REAR CAMBER Rear camber settings on this vehicle are determined at the time the vehicle is designed, by the location of the vehicle's suspension components. This is referred to as Net Build. The result is no required adjustment of camber after the vehicle is built or when servicing the suspension components. Thus, when performing a wheel alignment, rear camber is not considered an adjustable angle. CAUTION: Do not attempt to adjust the vehicle's wheel alignment by heating or bending any of the suspension components. FRONT CAMBER AND CASTER Front camber and caster settings on this vehicle are determined at the time the vehicle is designed, by the location of the vehicle's suspension components. This is referred to as Net Build. The result is no required adjustment of camber and caster after the vehicle is built or when servicing the suspension components. Thus, when performing a wheel alignment, caster and camber are not normally considered adjustable angles but some adjustment can be made. Camber and caster should be checked to ensure they meet vehicle specifications. If individual front camber or caster is found not to meet alignment specifications, each can be adjusted by shifting the front crossmember or by using an available service adjustment bolt package. If an adjustment bolt package installation is necessary, inspect the suspension components for any signs of damage or bending first. CAUTION: Do not attempt to adjust the vehicle's wheel alignment by heating or bending any of the suspension components. ADJUSTMENT BY SHIFTING CROSSMEMBER CAUTION: Always use care when shifting crossmember to avoid damaging other components on the vehicle. 1. Loosen the four bolts fastening the front crossmember to the frame just enough to allow movement of the crossmember. 2. Loosen the bolts fastening the fore/aft crossmember to the frame just enough to allow movement of the crossmember. CAUTION: When shifting the front crossmember, keep in mind that the front and rear engine mounts are attached to the front crossmember and fore/aft crossmember and should be inspected following the crossmember shift to make sure they are properly aligned. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel Alignment > Page 6498 3. Shift front crossmember as necessary (See following tables) to bring camber or caster into specifications. When shifting crossmember, use care not to move other angles (camber or caster) that are within specifications, out of specifications. Front Camber Adjustment By Shifting Crossmember Front Caster Adjustment By Shifting Crossmember 4. Tighten all previously loosened fasteners (bolts) securing the crossmember to the vehicle to specifications. 5. Jounce the rear, then front of the vehicle an equal amount of times. 6. Measure camber and caster. If camber and caster are within specifications, proceed to TOE. If camber cannot be brought into specifications, perform the CAMBER ADJUSTMENT BOLT PACKAGE INSTALLATION below. CAMBER ADJUSTMENT BOLT PACKAGE INSTALLATION The camber adjustment bolt package contains new bolts and nuts for attaching the strut clevis bracket to the steering knuckle. The bolts contained in the package are slightly undersize allowing for movement between the strut clevis bracket and the steering knuckle. The movement allowed by the undersize bolts provide approximately two degrees of camber adjustment per side of the vehicle. To install and adjust the camber adjustment bolt package, follow the procedure below. 7. Raise the vehicle until its tires are not supporting the weight of the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel Alignment > Page 6499 8. Remove the wheel mounting nuts (3), then the front tire and wheel assembly (1). CAUTION: The strut clevis-to-knuckle attaching bolt shanks are serrated and must not be turned during removal. Remove the nuts while holding the bolts stationary, then tap the bolts out using a punch. 9. Remove the original upper bolt (1) and nut (3) attaching the strut clevis bracket (2) to the knuckle (5). 10. Install a bolt from the adjustment package into the hole where the original bolt was removed. Install the bolt as indicated. 11. Install a nut provided in adjustment package on the replacement bolt. Tighten the nut until it's snug, but still allows the knuckle to slide in the clevis bracket. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel Alignment > Page 6500 12. Remove the original lower bolt (6) and nut (4) attaching the strut clevis bracket (2) to the knuckle (5). 13. Install a bolt from the adjustment package into the bottom hole of the strut clevis bracket. Install the bolt as indicated. 14. Install a nut provided in adjustment package on the replacement bolt. Tighten the nut until it's snug, but still allows the knuckle to slide in the clevis bracket. 15. Install the tire and wheel assembly (1). Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 16. Perform the above procedure to opposite strut as required. 17. Lower the vehicle and jounce the front and rear of the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel Alignment > Page 6501 18. Adjust the front camber to the preferred setting by pushing or pulling on the top of the tire. When camber is set to specifications, tighten the upper and lower strut clevis-to-knuckle attaching bolt nuts (3, 4) enough to hold the adjustment. Again jounce the front and rear of the vehicle, then verify the camber settings. 19. Tighten the front strut clevis-to-knuckle attaching bolt nuts (3, 4) to 84 Nm (62 ft. lbs.). 20. Once camber is within specifications, adjust toe to meet the preferred specification setting. Refer to FRONT TOE within this wheel alignment service procedure. TOE 1. Center the steering wheel and lock it in place using a steering wheel clamp. NOTE: When setting toe, make sure to set rear toe to the preferred specifications before setting front toe to the preferred specifications REAR TOE NOTE: Perform the following at each rear wheel as necessary. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel Alignment > Page 6502 2. While holding the cam bolt head (3) stationary, loosen the toe link mounting cam bolt nut (1). 3. Rotate the cam bolt head (3) left or right until the rear wheel toe for that rear wheel is set to the preferred specification. 4. While holding the cam bolt head (3) stationary, tighten the toe link mounting cam bolt nut (1) to 25 Nm (18 ft. lbs.). FRONT TOE NOTE: Perform the following at each front wheel as necessary. CAUTION: Do not twist the inner tie rod-to-steering gear boot (bellows) while turning the inner tie rod during front toe adjustment. It may be necessary to remove the clamp where the boot meets the inner tie rod. 5. Loosen the tie rod adjusting jam nut (1). Grasp the inner tie rod (3) and rotate it one way or the other until the front wheel toe is set to the preferred specification. 6. Tighten the tie rod adjusting jam nut to of 75 Nm (55 ft. lbs.). 7. Make sure the inner tie rod-to-steering gear boot is not twisted. If removed, reinstall the clamp where the boot meets the inner tie rod. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel Alignment > Page 6503 8. Remove the steering wheel clamp. 9. Remove the alignment equipment. 10. Road test the vehicle to verify the steering wheel is straight and the vehicle does not pull or wander. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel Alignment > Page 6504 Alignment: Service and Repair Curb Height Measurement CURB HEIGHT MEASUREMENT The wheel alignment is to be checked and all alignment adjustments made with the vehicle at its required curb height specification. Vehicle height is to be checked with the vehicle on a flat, level surface, preferably a vehicle alignment rack. The tires are to be inflated to the recommended pressure. All tires are to be the same size as standard equipment. Vehicle height is checked with the fuel tank full of fuel, and no passenger or luggage compartment load. Vehicle height is not adjustable. If the measurement is not within specifications, inspect the vehicle for bent or weak suspension components. Compare the parts tag on the suspect coil spring(s) to the parts book and the vehicle sales code, checking for a match. Once removed from the vehicle, compare the coil spring height to a correct new or known good coil spring. The heights should vary if the suspect spring is weak. NOTE: Prior to reading the curb height measurement, the front and rear of the vehicle must be jounced to settle the suspension. Induce jounce by pushing down on the center of the bumper (fascia), using care not to damage the vehicle, moving the vehicle up and down, gradually increasing the suspension travel with each stroke. Release the bumper at the bottom of each stroke, repeating this action several times. Perform this to both front and rear suspensions an equal amount of times. Measure curb height as follows: 1. Jounce the vehicle. Refer to above note. NOTE: On some vehicles it may be necessary to remove an engine belly pan in order to gain access to the lower control arm pivot bolt. 2. FRONT - On each side of the vehicle, measure the distance (2) from the lower control arm rear (vertical) pivot bolt head (1) to the floor or alignment rack/lift runway surface. It may be necessary to measure to the bottom of a straight edge (3), placed from lift runway to runway, to get an accurate measurement. 3. REAR - On each side of the vehicle, measure the distance (2) from the center of the outboard trailing arm-to-body mounting bolt (1) to the floor or Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel Alignment > Page 6505 alignment rack/lift runway surface. 4. Compare the measurements to specifications listed in the following CURB HEIGHT SPECIFICATIONS chart. Maximum left-to-right differential is not to exceed 12.5 mm (0.5 in.). 5. If curb height is found to be out of specification and there is no sign of excessive body damage, curb height can be changed by replacing the applicable spring with a spring offering a different check load. Curb Height Specifications Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Description and Operation > Description Steering Column Control Module: Description and Operation Description DESCRIPTION This vehicle is equipped with a Steering Column Control Module (SCCM) The SCCM is secured near the top of the steering column below the steering wheel and is completely concealed beneath the steering column shrouds. It is installed as a modular unit that supports the left (lighting) multi-function switch (1) and right (wiper) multi-function switch (6). The controls for each of these switches extend through appropriate clearance holes provided in the steering column shrouds. The microprocessor-based Steering Control Module (SCM) (2) utilizes integrated circuitry and information carried on the Controller Area Network (CAN) data bus along with several hard wired analog and multiplexed inputs to monitor both the right and left multi-function switches. The SCCM uses a Local Interconnect Network (LIN) data bus for exterior lighting and wiper functions. The LIN data is sent to the Cab Compartment Node (CCN) and the CCN then sends it out on the CAN data bus. The SCCM is available for service replacement as a unit or each individual component: - Clockspring (with integral Steering Angle Sensor if equipped) - Left Multi-Function Switch - Right Multi-Function Switch Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Description and Operation > Description > Page 6512 Steering Column Control Module: Description and Operation Operation OPERATION The Steering Control Module (SCM) communicates over the Local Interconnect Network (LIN) data bus with other electronic modules in the vehicle and/or a diagnostic scan tool. The horn switch circuits pass through the clockspring to the Cab Compartment Node (CCN) and the CCN sends a CAN message to the Totally Integrated Power Module (TIPM) to control the horn. The CCN stores Diagnostic Trouble Codes (DTC's) for the SCM. The right (wiper) multi-function switch has several inputs to the CCN. The SCM is connected to a fused B(+) circuit and receives a path to ground at all times. These connections allow it to remain functional regardless of the ignition switch position. The driver airbag squib circuits of the clockspring, the horn, and the speed control switch circuits pass through the SCM, but the SCM does not monitor, and has no control outputs related to these circuits. Any other input to the SCM that would cause a vehicle system to function but does not require that the ignition switch be in the On position, such as turning on the lights or sounding the horn, prompts the SCM to wake up and transmit on the CAN data bus. The most reliable, efficient, and accurate means to diagnose the SCM, the CAN data bus, the hard wired inputs or the electronic communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. The integral SCM is not available for separate service replacement. If found inoperative or defective, the entire left (lighting) multi-function switch must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Service and Repair > Removal Steering Column Control Module: Service and Repair Removal REMOVAL SCCM 1. Place the front road wheels in the STRAIGHT-AHEAD position. 2. Open hood. 3. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. 4. Remove steering wheel. 5. Remove upper and lower steering column shrouds to gain access to the Steering Column Control Module (SCCM). 6. Lock the clockspring rotor in the center position as follows: Insert a grenade pin through the hole in the rotor at the 10 o'clock position. 7. Remove the three screws (1) to the Steering Column Control Module (SCCM) (3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Service and Repair > Removal > Page 6515 8. Disconnect the electrical connectors (2) between the SCCM (1) and the instrument panel wiring harness at the base of the SCCM and remove from column. NOTE: If only removing the SCCM from column, there is no need to continue to next step. DISASSEMBLY 1. Remove the left multi-function switch stalk retaining screw (2). 2. Pull the left stalk out of the SCCM. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Service and Repair > Removal > Page 6516 3. Disconnect the left stalk electrical connector. 4. Separate the left switch from the SCCM. 5. Remove the one right multi-function switch retaining screw. 6. Pull right switch out of SCCM. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Service and Repair > Removal > Page 6517 7. Disconnect the right switch electrical connector. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Service and Repair > Removal > Page 6518 Steering Column Control Module: Service and Repair Installation INSTALLATION NOTE: If SCCM is already assembled and needs to be installed, bypass ASSEMBLY and proceed with SCCM STEP 1. ASSEMBLY 1. Connect the right stalk electrical connector. 2. Slide the right stalk into the groove and install the one retaining screw. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Service and Repair > Removal > Page 6519 3. Connect the left stalk switch electrical connector. 4. Install the left stalk switch retaining screw. SCCM Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Service and Repair > Removal > Page 6520 1. Position the SCCM (3) over the steering column shaft (2). 2. Install the three screws (1). 3. Connect the electrical connectors (2) to the instrument panel harness, ensure wiring is properly routed. Then check that the connectors, locking tabs are properly engaged. 4. Install steering column shrouds. Be sure all wires are inside of shrouds. 5. Install steering wheel ensuring the flats on hub align with the clockspring. Pull the airbag leads through the larger slot. Ensure leads do not get pinched under the steering wheel. NOTE: There is a small wire harness in the steering wheel and it contains the horn circuits and speed control circuits. 6. Connect the speed control and horn wire connector into the clockspring. 7. Pull the grenade pin out of the clockspring. 8. Install the driver airbag. WARNING: Do not connect the battery negative cable. Personal injury or death may result if the system test is not performed first. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations Steering Control Module: Locations Component ID: 162 Component : MODULE-STEERING CONTROL Connector: Name : MODULE-STEERING CONTROL C1 Color : WHITE # of pins : 4 Pin Description Circuit 1 GROUND Z937 20BK/YL Pin Description Circuit 1 GROUND Z936 20BK/LB 2 FUSED B(+) (I.O.D.) A411 20RD/LG 3 LIN BUS D506 20WT/DG 4 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY Component Location - 28 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 6524 Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 6525 Connector: Name : MODULE-STEERING CONTROL C2 Color : WHITE # of pins : 6 Pin Description Circuit 1 RADIO CONTROL MUX X20 20GY/WT 2 RADIO CONTROL RETURN Y13 20DG/RD 3 HORN SWITCH SENSE X3 20DG/VT 4 S/C SIGNAL 2 V72 20OR/VT 5 S/C SWITCH GROUND V937 20VT/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 6526 6 S/C SIGNAL 1 V71 20VT/OR Component Location - 28 Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 6527 Connector: Name : MODULE-STEERING CONTROL C4 Color : WHITE # of pins : 4 Pin Description Circuit 1 DRIVER SQUIB 2 LINE 1 R63 18LG/BK 2 DRIVER SQUIB 2 LINE 2 R61 18LG/VT 3 DRIVER SQUIB 1 LINE 1 R45 18LG/RD 4 DRIVER SQUIB 1 LINE 2 R43 18LG/BR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 6528 Component Location - 28 Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 6529 Connector: Name : MODULE-STEERING CONTROL C5 Color : WHITE # of pins : 6 Pin Description Circuit 1 RADIO CONTROL MUX X20 20GY Pin Description Circuit 1 RADIO CONTROL MUX X20 20GY 2 RADIO CONTROL RETURN Y13 20BK Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 6530 2 RADIO CONTROL RETURN Y13 20BK 3 HORN SWITCH SENSE X3 20DB 4 S/C SIGNAL 2 V72 20PK 5 S/C SIGNAL 1 V71 20VT 6 S/C SWITCH GROUND V937 20YL Component Location - 28 Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 6531 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 6532 Steering Control Module: Diagrams Component ID: 162 Component : MODULE-STEERING CONTROL Connector: Name : MODULE-STEERING CONTROL C1 Color : WHITE # of pins : 4 Pin Description Circuit 1 GROUND Z937 20BK/YL Pin Description Circuit 1 GROUND Z936 20BK/LB 2 FUSED B(+) (I.O.D.) A411 20RD/LG 3 LIN BUS D506 20WT/DG 4 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY Component Location - 28 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 6533 Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 6534 Connector: Name : MODULE-STEERING CONTROL C2 Color : WHITE # of pins : 6 Pin Description Circuit 1 RADIO CONTROL MUX X20 20GY/WT 2 RADIO CONTROL RETURN Y13 20DG/RD 3 HORN SWITCH SENSE X3 20DG/VT 4 S/C SIGNAL 2 V72 20OR/VT 5 S/C SWITCH GROUND V937 20VT/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 6535 6 S/C SIGNAL 1 V71 20VT/OR Component Location - 28 Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 6536 Connector: Name : MODULE-STEERING CONTROL C4 Color : WHITE # of pins : 4 Pin Description Circuit 1 DRIVER SQUIB 2 LINE 1 R63 18LG/BK 2 DRIVER SQUIB 2 LINE 2 R61 18LG/VT 3 DRIVER SQUIB 1 LINE 1 R45 18LG/RD 4 DRIVER SQUIB 1 LINE 2 R43 18LG/BR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 6537 Component Location - 28 Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 6538 Connector: Name : MODULE-STEERING CONTROL C5 Color : WHITE # of pins : 6 Pin Description Circuit 1 RADIO CONTROL MUX X20 20GY Pin Description Circuit 1 RADIO CONTROL MUX X20 20GY 2 RADIO CONTROL RETURN Y13 20BK Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 6539 2 RADIO CONTROL RETURN Y13 20BK 3 HORN SWITCH SENSE X3 20DB 4 S/C SIGNAL 2 V72 20PK 5 S/C SIGNAL 1 V71 20VT 6 S/C SWITCH GROUND V937 20YL Component Location - 28 Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 6540 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Description Steering Mounted Controls Communication Module: Description and Operation Description DESCRIPTION This vehicle is equipped with a Steering Column Control Module (SCCM) The SCCM is secured near the top of the steering column below the steering wheel and is completely concealed beneath the steering column shrouds. It is installed as a modular unit that supports the left (lighting) multi-function switch (1) and right (wiper) multi-function switch (6). The controls for each of these switches extend through appropriate clearance holes provided in the steering column shrouds. The microprocessor-based Steering Control Module (SCM) (2) utilizes integrated circuitry and information carried on the Controller Area Network (CAN) data bus along with several hard wired analog and multiplexed inputs to monitor both the right and left multi-function switches. The SCCM uses a Local Interconnect Network (LIN) data bus for exterior lighting and wiper functions. The LIN data is sent to the Cab Compartment Node (CCN) and the CCN then sends it out on the CAN data bus. The SCCM is available for service replacement as a unit or each individual component: - Clockspring (with integral Steering Angle Sensor if equipped) - Left Multi-Function Switch - Right Multi-Function Switch Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Description > Page 6545 Steering Mounted Controls Communication Module: Description and Operation Operation OPERATION The Steering Control Module (SCM) communicates over the Local Interconnect Network (LIN) data bus with other electronic modules in the vehicle and/or a diagnostic scan tool. The horn switch circuits pass through the clockspring to the Cab Compartment Node (CCN) and the CCN sends a CAN message to the Totally Integrated Power Module (TIPM) to control the horn. The CCN stores Diagnostic Trouble Codes (DTC's) for the SCM. The right (wiper) multi-function switch has several inputs to the CCN. The SCM is connected to a fused B(+) circuit and receives a path to ground at all times. These connections allow it to remain functional regardless of the ignition switch position. The driver airbag squib circuits of the clockspring, the horn, and the speed control switch circuits pass through the SCM, but the SCM does not monitor, and has no control outputs related to these circuits. Any other input to the SCM that would cause a vehicle system to function but does not require that the ignition switch be in the On position, such as turning on the lights or sounding the horn, prompts the SCM to wake up and transmit on the CAN data bus. The most reliable, efficient, and accurate means to diagnose the SCM, the CAN data bus, the hard wired inputs or the electronic communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. The integral SCM is not available for separate service replacement. If found inoperative or defective, the entire left (lighting) multi-function switch must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front Tire Pressure Monitor Receiver / Transponder: Locations Transponder-Tire Pressure-Left Front Component ID: 361 Component : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Connector: Name : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Color : YELLOW # of pins : 6 Qualifier : (TIRE PRESSURE MONITOR) Pin Description Circuit 1 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 GROUND Z904 20BK/OR 4 GROUND Z904 20BK/OR 5-6-- Component Location - 13 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 6551 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 6552 Tire Pressure Monitor Receiver / Transponder: Locations Transponder-Tire Pressure-Left Rear Component ID: 362 Component : TRANSPONDER-TIRE PRESSURE-LEFT REAR Connector: Name : TRANSPONDER-TIRE PRESSURE-LEFT REAR Color : BLACK # of pins : 6 Qualifier : (TIRE PRESSURE MONITOR) Pin Description Circuit 1 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 GROUND Z904 20BK/OR 4-5-6-- Component Location - 58 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 6553 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 6554 Tire Pressure Monitor Receiver / Transponder: Locations Transponder-Tire Pressure-Right Rear Component ID: 363 Component : TRANSPONDER-TIRE PRESSURE-RIGHT REAR Connector: Name : TRANSPONDER-TIRE PRESSURE-RIGHT REAR Color : BLACK # of pins : 6 Qualifier : (TIRE PRESSURE MONITOR) Pin Description Circuit 1 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 GROUND Z965 20BK/GY 4-5-6 GROUND Z965 20BK/GY Component Location - 59 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 6555 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front Tire Pressure Monitor Receiver / Transponder: Diagrams Transponder-Tire Pressure-Left Front Component ID: 361 Component : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Connector: Name : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Color : YELLOW # of pins : 6 Qualifier : (TIRE PRESSURE MONITOR) Pin Description Circuit 1 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 GROUND Z904 20BK/OR 4 GROUND Z904 20BK/OR 5-6-- Component Location - 13 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 6558 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 6559 Tire Pressure Monitor Receiver / Transponder: Diagrams Transponder-Tire Pressure-Left Rear Component ID: 362 Component : TRANSPONDER-TIRE PRESSURE-LEFT REAR Connector: Name : TRANSPONDER-TIRE PRESSURE-LEFT REAR Color : BLACK # of pins : 6 Qualifier : (TIRE PRESSURE MONITOR) Pin Description Circuit 1 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 GROUND Z904 20BK/OR 4-5-6-- Component Location - 58 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 6560 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 6561 Tire Pressure Monitor Receiver / Transponder: Diagrams Transponder-Tire Pressure-Right Rear Component ID: 363 Component : TRANSPONDER-TIRE PRESSURE-RIGHT REAR Connector: Name : TRANSPONDER-TIRE PRESSURE-RIGHT REAR Color : BLACK # of pins : 6 Qualifier : (TIRE PRESSURE MONITOR) Pin Description Circuit 1 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 GROUND Z965 20BK/GY 4-5-6 GROUND Z965 20BK/GY Component Location - 59 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 6562 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Description Tire Pressure Monitor Receiver / Transponder: Description and Operation Description DESCRIPTION A transponder, sometimes referred to as a trigger module, is located in three of the four wheel wells (behind the wheelhouse splash shields) of a vehicle equipped with Premium TPM. These transponders are used to provide the Wireless Control Module (WCM), commonly referred to as the Sentry Key Remote Entry Module (SKREEM), with the location of the tire pressure sensors on the vehicle. A fourth transponder is not necessary in the remaining wheel well due to the process-of-elimination theory. Once the system knows the location of the first three sensors it assumes the location of the fourth tire pressure sensor. On this vehicle, there is a transponder located in the left front, left rear, and right rear wheelhouse. There is not a transponder located in the right front wheelhouse. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Description > Page 6565 Tire Pressure Monitor Receiver / Transponder: Description and Operation Operation OPERATION On vehicles equipped with the premium TPM system, the Wireless Control Module (WCM), commonly referred to as the Sentry Key Remote Entry Module (SKREEM), uses transponders (trigger modules) located in three of the four wheel wells on the vehicle to provide it with the location of the tire pressure sensors on the vehicle. Like the base system, the WCM receives RF signals from all four rotating wheel speed sensors. When the WCM needs to know which sensor is located at a particular location on the vehicle, it directs the transponder at that location to send out a low frequency signal to excite the nearby sensor. The WCM then receives that excited signal and knows where that sensor is located. This auto-locating process only happens in the first 10 minutes of any WCM cycle while traveling at speeds above 20 mph (32 km/h). (The auto-locating process will start again only if the vehicle has been shut off for approximately 20 minutes or longer). Once the WCM has performed this to the three locations that have transponders, it uses the process-of-elimination theory to know that the fourth sensor ID signal is coming from. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Removal Tire Pressure Monitor Receiver / Transponder: Service and Repair Removal Front FRONT 1. Remove the wheelhouse splash shield at the transponder requiring service. 2. Disconnect the wiring harness connector (2) at the transponder (1). 3. Remove the mounting nuts (3), then remove the transponder (1). Rear REAR 1. Remove the wheelhouse splash shield at the transponder requiring service. 2. Disconnect the wiring harness connector (3) at the transponder (1). 3. Remove the mounting nuts (2), then remove the transponder (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Removal > Page 6568 Tire Pressure Monitor Receiver / Transponder: Service and Repair Installation Front FRONT 1. Position the transponder (1) and install the mounting nuts (3). 2. Connect the wiring harness connector (2) to the transponder (1). 3. Install the wheelhouse splash shield and all components removed to access it. 4. Perform the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests Rear REAR 1. Position the transponder (1) and install the mounting nuts (2). 2. Connect the wiring harness connector (3) to the transponder (1). 3. Install the rear wheelhouse splash shield and all components removed to access it. 4. Perform the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Technical Service Bulletins > Steering - ESP Lamp On Possible DTC C121A/C2205 Steering Angle Sensor: Technical Service Bulletins Steering - ESP Lamp On Possible DTC C121A/C2205 NUMBER: 08-010-07 GROUP: Vehicle Performance DATE: May 17, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: DTC's C121A / C2205 - Steering Angle Sensor - Not Initialized / Internal OVERVIEW: This bulletin involves selectively erasing and reprogramming the Steering Angle Sensor (SAS) with new software. MODELS: 2007 (JK) Wrangler 2007 (JS) Sebring 2007 (KA) Nitro 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to vehicles built on or before April 12, 2007 (MDH 0412XX). SYMPTOM/CONDITION: The vehicle operator may experience an illumination of the Electronic Stability Program (ESP) lamp on the vehicle instrument cluster. The ESP lamp illumination may be due to the following Diagnostic Trouble Codes (DTC's): C121A - Steering Angle Sensor Not Initialized C2205 - Steering Angle Sensor Internal This condition, and DTC's, may be intermittent. If the above DTC's occur during a drive cycle, then the ESP lamp will remain illuminated until the end of that drive cycle (key off). DIAGNOSIS: Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Technical Service Bulletins > Steering - ESP Lamp On Possible DTC C121A/C2205 > Page 6575 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 7.04 SPI or higher. The software release level is visible in the blue header at the top of the StarSCAN® screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. For instruction on setting up your StarSCAN® for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU (SAS) part number. Using the StarSCAN(R) at the "Home screen: a. Select "ECU View" b. Touch the screen to highlight the ECU (SAS) in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Technical Service Bulletins > Steering - ESP Lamp On Possible DTC C121A/C2205 > Page 6576 k. When the update is complete, select "OK". NOTE: Due to the ECU (SAS) programming procedure, a DTC may be set in other electronic modules within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Technical Service Bulletins > Steering - ESP Lamp On Possible DTC C121A/C2205 Steering Angle Sensor: Technical Service Bulletins Steering - ESP Lamp On Possible DTC C121A/C2205 NUMBER: 08-010-07 GROUP: Vehicle Performance DATE: May 17, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: DTC's C121A / C2205 - Steering Angle Sensor - Not Initialized / Internal OVERVIEW: This bulletin involves selectively erasing and reprogramming the Steering Angle Sensor (SAS) with new software. MODELS: 2007 (JK) Wrangler 2007 (JS) Sebring 2007 (KA) Nitro 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to vehicles built on or before April 12, 2007 (MDH 0412XX). SYMPTOM/CONDITION: The vehicle operator may experience an illumination of the Electronic Stability Program (ESP) lamp on the vehicle instrument cluster. The ESP lamp illumination may be due to the following Diagnostic Trouble Codes (DTC's): C121A - Steering Angle Sensor Not Initialized C2205 - Steering Angle Sensor Internal This condition, and DTC's, may be intermittent. If the above DTC's occur during a drive cycle, then the ESP lamp will remain illuminated until the end of that drive cycle (key off). DIAGNOSIS: Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Technical Service Bulletins > Steering - ESP Lamp On Possible DTC C121A/C2205 > Page 6582 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 7.04 SPI or higher. The software release level is visible in the blue header at the top of the StarSCAN® screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. For instruction on setting up your StarSCAN® for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU (SAS) part number. Using the StarSCAN(R) at the "Home screen: a. Select "ECU View" b. Touch the screen to highlight the ECU (SAS) in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Technical Service Bulletins > Steering - ESP Lamp On Possible DTC C121A/C2205 > Page 6583 k. When the update is complete, select "OK". NOTE: Due to the ECU (SAS) programming procedure, a DTC may be set in other electronic modules within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions Tire Pressure Sensor: Service Precautions CAUTION CAUTION: The use of tire sealants is strictly prohibited for vehicles equipped with the Tire Pressure Monitoring system. Tire sealants can clog tire pressure sensors. CAUTION: Any time a sensor is to be installed in a wheel, it is necessary to install a new sensor-to-wheel seal, metal washer and valve stem nut, to ensure air tight sealing. CAUTION: Tire pressure sensor valve stem caps and cores are specially designed for the sensors. Due to risk of corrosion, do not use a standard valve stem cap or core in a tire pressure sensor in place of the original equipment style sensor cap and core. CAUTION: When installing the valve core, be sure to tighten the core to specifications. Overtightening by a little as three or four inch pounds can damage the sensor. CAUTION: Do not attempt to install a tire pressure sensor in an aftermarket wheel. Use tire pressure sensors in original style factory wheels only. If aftermarket wheels are installed, and therefore do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. NOTE: TPM thresholds have been established for the original tire size equipped on the vehicle. Use original size tires only to maintain system accuracy. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Description Tire Pressure Sensor: Description and Operation Description DESCRIPTION On vehicles equipped with Tire Pressure Monitoring (TPM), one tire pressure sensor (6) is mounted to each wheel (5) in place of the traditional tire valve stem. Each sensor has an internal battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the sensor must be replaced. The TPM system operates on a 315 MHz radio frequency. The 315 MHz sensors can be easily identified by a white outline oval (black center) insignia (3) on the sensor body. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Description > Page 6590 The Export TPM system operates on a 433 MHz radio frequency. The 433 MHz sensors can be easily identified by either a solid white oval insignia (3) on the body or... ... a solid white oval insignia (3) with 433 printed in the center. The sensors are identical except for the oval insignia. The 433 MHz sensors can either have a black or grey sensor body. CAUTION: Although 315 MHz and 433 MHz sensors are identical in size and shape, they are not interchangeable. Always make sure the correct sensor is being used. NOTE: Sensors may be identified by valve stem cap color. From the factory, 315 MHz sensors have a gray valve stem cap while 433 MHz sensors have a black valve stem cap. Otherwise, once mounted inside a tire and wheel assembly you are not able to visually tell the difference between a 315 MHz and 433 MHz sensor. At that point, the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool may be used to identify the sensor frequency or the tire can be dismounted allowing visual inspection of the sensor body. The TPM sensors are designed for original style factory wheels. It is not recommended to install a tire pressure sensor in an aftermarket wheel (This could cause sealing and system performance issues). Do not attempt to install a tire pressure sensor in an aftermarket wheel. If aftermarket wheels are installed and do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Description > Page 6591 The serviceable components of the tire pressure sensor are: - Sensor-To-Wheel Seal (2) and Metal Washer (1) - Valve Stem Cap (4) - Valve Stem Core - Valve Stem Nut (with pressed-in washer) (3) NOTE: Any time a sensor is installed on a wheel, a new Sensor-To-Wheel Seal (2), Metal Washer (1) and Valve Stem Nut (3) must be installed to ensure air tight sealing. A service kit is available. The valve stem caps and cores are specifically designed for the tire pressure monitoring sensors. Although similar to standard valve stem caps and cores, they are different. The valve stem cap has a special seal inside to keep moisture and corrosion out. The valve stem core has a special nickel coating to protect from corrosion. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Description > Page 6592 Tire Pressure Sensor: Description and Operation Operation OPERATION The battery operated tire pressure sensor is both a transmitter and a receiver. The TPM sensor can be forced to transmit by using a special tool such as a TPM-RKE Analyzer, or from a transponder. The TPM-RKE Analyzer has the ability to change the sensor's operating mode to PARK MODE and to help diagnose a faulty TPM sensor. Using a TPM-RKE Analyzer can take up to a minute to force a transmission from a sensor. The TPM sensor can be in one of the following operating modes: - SLEEP MODE - This is the operating mode of a new TPM sensor. If placed on the vehicle as a road tire, the sensor will transmit once every 20 seconds when the vehicle is driven at speeds over 15 mph (24 km/h). Driving the vehicle continuously at this speed for more then 4 minutes will change the sensor state to DRIVE MODE. Stopping the vehicle for 20 minutes will change the sensor state to PARK MODE. If the vehicle is not moving, the sensor will only transmit on a pressure change greater then 1 psi (6.9 kPa). - PARK MODE - This is the correct operating mode when the vehicle is not moving. The sensor will transmit once every 13 hours to update the WCM, or will transmit on a 1 psi (6.9 kPa) delta change. The sensors will internally take a measurement of the tire pressure every minute to determine a change in tire pressure. - 30 BLOCK MODE - If the vehicle has been stopped for more then 20 minutes, or if the sensor's operating mode was forced to PARK MODE using a TPM-RKE Analyzer, the sensor's operating mode will transition from PARK MODE to 30 BLOCK MODE once the vehicle is driven over 15 mph. In this mode, the sensor will transmit once every 15 seconds when the vehicle is driven at speeds over 15 mph (24 km/h) for the first 30 transmissions. After about 8 minutes of continuous driving above 15 mph (24 km/h), the sensor's mode will change to DRIVE MODE. - DRIVE MODE - In this mode, the sensor will transmit once every minute when the vehicle is driven at speeds over 15 mph (24 km/h). At any time the vehicle speed drops below 15 mph, the sensor will not transmit. The sensor mode will still be in drive mode when the sensor reaches speeds over 15 mph (24 km/h), unless the vehicle has been stationary for more then 20 minutes. Each sensor's (transmitter) broadcast is uniquely coded so that the wireless control module (WCM) can monitor the state of each of the sensors on the four rotating road wheels. The WCM can automatically learn and store the sensor's ID while driving "within 10 minutes continuously above 15 mph (24 Km/h)" after a sensor has been replaced. The vehicle must be stationary for more then 20 minutes in order to initiate the learning sequence. The WCM can also learn the sensor's ID using the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool following the procedure listed in the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Removal Tire Pressure Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Remove wheel mounting nuts (3), then tire and wheel assembly (1). CAUTION: The cap used on this valve stem contains an O-ring seal to prevent contamination and moisture from entering the valve stem. Retain this valve stem cap for reuse. Do not substitute a regular valve stem cap in its place. CAUTION: The valve stem used on this vehicle is made of aluminum and the core is nickel plated brass. The original valve stem core must be reinstalled and not substituted with a valve stem core made of a different material. This is required to prevent corrosion in the valve stem caused by the different metals. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Removal > Page 6595 3. Dismount tire from wheel following tire changer manufacturers instructions while paying special attention to the following to avoid damaging the pressure sensor: a. When breaking the tire bead loose from the wheel rim, avoid using the Bead Breaker in the area of the sensor. That includes both front and rear beads of the tire. b. When preparing to dismount the tire from the wheel, carefully insert the mounting/dismounting tool at the valve stem ± 10°, then proceed to dismount the tire from the wheel. Use this process on both the upper and lower tire beads. 4. Remove sensor nut (3) retaining sensor to wheel. While removing nut, hold pressure against rear of metal valve stem to keep valve stem from pushing rearward, damaging antenna strap. 5. Remove sensor (1) from wheel (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Removal > Page 6596 Tire Pressure Sensor: Service and Repair Installation INSTALLATION NOTE: Before reinstalling an existing tire pressure sensor, replace seal (2) and metal washer (1) at base of sensor valve stem (6) to ensure proper sealing. 1. Wipe area clean around sensor/valve stem mounting hole in wheel (5). Make sure surface of wheel is not damaged. CAUTION: To avoid damaging sensor antenna strap (1), hold pressure against rear of metal valve stem (2) while sensor is inserted through wheel mounting hole and nut is installed. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Removal > Page 6597 2. Insert sensor (1) through wheel (2) as shown keeping pressure against rear of metal valve stem (See Arrow). Potted side of sensor is to be positioned toward wheel. Do not attempt to mount sensor otherwise, damage may occur. 3. Install sensor nut (with pressed-in washer) (3) by hand. NOTE: Before tightening sensor nut, push downward on sensor housing (2) in an attempt to make it flush with interior contour of wheel (1). 4. While holding sensor in position, tighten sensor nut to 8 Nm (71 in. lbs.). CAUTION: Over-torquing the sensor nut by as little as 12 Nm (106 in. lbs.) may result in sensor separation from the valve stem. Under this condition, the sensor may still function. However, the condition should be corrected immediately. 5. Mount tire on wheel following tire changer manufacturers instructions, paying special attention to the following to avoid damaging tire pressure sensor: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Removal > Page 6598 a. Rotating Wheel Tire Changers - Once the wheel is mounted to the changer, position the sensor valve stem (2) approximately 210° from the head of the changer (located at 1) in a clockwise direction before rotating the wheel (also in a clockwise direction) to mount the tire. Use this procedure on both the upper and lower tire beads. b. Rotating Tool Tire Changers - Position the wheel on the changer so that the sensor valve stem (1) is located approximately 210° clockwise from the installation end of the mounting/dismounting tool (2) once the tool is mounted for tire installation. Make sure the sensor is clear of the lower bead breaker area (3) to avoid damaging the sensor when the breaker rises. Rotate the tool (2) in a counterclockwise direction to mount the tire. Use this procedure on both the upper and lower tire beads. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Removal > Page 6599 6. Adjust air pressure to that listed on Tire Inflation Pressure Label (Placard) provided with vehicle (applied to driver's side B-pillar). Make sure original style and color valve stem cap is securely installed to keep moisture out of sensor. 7. Install tire and wheel assembly (1) on vehicle. Tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 8. Lower vehicle. 9. Perform one of the following to make the system learn the new sensor ID. a. Use the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool to program the WCM/SKREEM with the tire pressure sensor ID. This is part of the TPM Diagnostic Verification Test. b. Once the vehicle has remained stationary for more than 20 minutes, drive vehicle for a minimum of 10 minutes while maintaining a continuous speed above 15 mph (24 km/h). During this time, the system will learn the new sensor ID. This is part of the TPM Diagnostic Verification Test. NOTE: If a sensor cannot be trained, refer to appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Description and Operation Front Steering Knuckle: Description and Operation DESCRIPTION The knuckle (1) is a single casting with legs machined for attachment to the front strut assembly on the top, lower control arm ball joint on the bottom, and steering linkage on the trailing end. The knuckle also has two machined, drilled and tapped legs on the leading end casting to support and align the front disc brake caliper adapter. The knuckle supports the wheel bearing (5) and hub (3). The hub is pressed into a sealed-for-life wheel bearing that is pressed into the knuckle. A snap ring also holds the bearing in place. A shield is pressed onto the knuckle behind the hub. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Description and Operation > Page 6604 Front Steering Knuckle: Testing and Inspection KNUCKLE The front suspension knuckle is not a repairable component of the front suspension. It must be replaced if found to be damaged in any way. If it is determined that the knuckle is bent when servicing the vehicle, no attempt is to be made to straighten the knuckle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal Front Steering Knuckle: Service and Repair Removal REMOVAL NOTE: Before proceeding, review all Warnings and Cautions. 1. Raise and support the vehicle. 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). 3. Remove the cotter pin (2) from the hub nut (3). 4. While a helper applies the brakes to keep the hub (1) from rotating, remove the hub nut (3) and washer (4) from the axle half shaft. 5. Access and remove the front brake rotor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 6607 6. Remove the routing clip (1) securing wheel speed sensor cable to the knuckle (4). 7. Remove the screw (2) fastening the wheel speed sensor head (3) to the knuckle (4). Pull the sensor head out of the knuckle. 8. Remove the nut (2) attaching the outer tie rod (7) to the knuckle (3). To do this, hold the tie rod end stud with a wrench while loosening and removing the nut with a standard wrench or crowfoot wrench. 9. Release the outer tie rod end (3) from the knuckle (2) using Remover (1), Special Tool 9360. 10. Remove the outer tie rod from the knuckle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 6608 11. Remove the nut (5) and pinch bolt (4) clamping the ball joint stud (6) to the knuckle (3). CAUTION: The strut assembly-to-knuckle attaching bolts (5) are serrated and must not be turned during removal. Proper removal is required. Refer to the following steps for the correct method. 12. While holding the bolt heads stationary, remove the two nuts (2) from the bolts (5) attaching the strut (3) to the knuckle (6). 13. Remove the two bolts (5) attaching the strut (3) to the knuckle (6) using a pin punch. CAUTION: Use care when separating the ball joint stud (4) from the knuckle (1), so the ball joint seal does not get cut. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 6609 14. Using an appropriate prying tool (2), separate the ball joint stud (4) from the knuckle (1) by prying down on lower control arm (3) and up against the ball joint boss on the knuckle. NOTE: Do not allow the half shaft (1) to hang by the inner C/V joint; it must be supported to keep the joint from separating during this operation. 15. Pull the knuckle (3) off the half shaft (1) outer C/V joint splines and remove the knuckle from the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 6610 Front Steering Knuckle: Service and Repair Installation INSTALLATION 1. Slide the hub of the knuckle (3) onto the splines of the halfshaft outer C/V joint (1). 2. Install the knuckle (3) onto the ball joint (6) stud aligning the bolt hole in the knuckle boss with the groove formed into the side of the ball joint stud. 3. Install a NEW ball joint stud pinch bolt (4) and nut (5). Tighten the nut to 82 Nm (60 ft. lbs.). CAUTION: The strut assembly-to-knuckle attaching bolts (2) are serrated and must not be turned during installation. Install the nuts while holding the bolts stationary in the steering knuckle. Refer to the following step. 4. Position the lower end of the strut assembly (3) in line with the upper end of the knuckle (6), aligning the mounting holes. Install the two mounting bolts (5). 5. Install the nuts (2) on the two bolts (5). While holding the bolts in place, tighten the nuts to 84 Nm (62 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 6611 6. Install the outer tie rod (7) ball stud into the hole in the knuckle (3) arm. Start the tie rod end-to-knuckle nut (2) onto the stud. While holding the tie rod end stud with a wrench, tighten the nut with a wrench or crowfoot wrench to 132 Nm (97 ft. lbs.). 7. Install the wheel speed sensor head (3) into the knuckle (4). Install the mounting screw (2) and tighten it to 12 Nm (106 in. lbs.). 8. Install the routing clip (1) securing the wheel speed sensor cable to the knuckle (4). 9. Install the brake rotor, disc brake caliper and adapter. 10. Clean all foreign matter from the threads of the halfshaft outer C/V joint. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 6612 11. Install the washer (4) and hub nut (3) on the end of the halfshaft and snug it. 12. While a helper applies the brakes to keep the hub (1) from rotating, tighten the hub nut (3) to 245 Nm (181 ft. lbs.). 13. Insert the cotter pin (2) through the notches in the nut and the hole in halfshaft. If the notches in the nut do not line up with the hole in the halfshaft, continue to tighten the nut until they do. Do not loosen the nut. 14. Wrap the cotter pin (2) ends tightly around the lock nut. 15. Install tire and wheel assembly (1). Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 16. Lower the vehicle. NOTE: If the original knuckle is being reinstalled, wheel alignment may not be necessary due to Net-Build design. 17. Perform wheel alignment as necessary. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Power Steering Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 6618 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 6619 Power Steering Fluid: Specifications Power Steering Fluid Type Mopar Power Steering Fluid +4 or Mopar Automatic Transmission Fluid. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 6620 Power Steering Fluid: Description and Operation DESCRIPTION The recommended fluid for the power steering system is Mopar(R) Power Steering fluid + 4 or Mopar(R) ATF+4 Automatic Transmission Fluid. Both fluids have the same material standard specifications (MS-9602). Mopar(R) ATF+4 (and Mopar(R) Power Steering fluid + 4), when new, is red in color. ATF+4 is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, ATF+4 will begin to look darker in color and may eventually become brown. THIS IS NORMAL. ATF+4 also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 6621 Power Steering Fluid: Testing and Inspection POWER STEERING FLUID LEVEL CHECKING WARNING: Fluid level should be checked with the engine OFF to prevent personal injury from moving parts and to assure an accurate fluid level reading. CAUTION: Mopar(R) Power Steering Fluid + 4 or Mopar(R) ATF+4 Automatic Transmission Fluid is to be used in the power steering system. Both fluids have the same material standard specifications (MS-9602). No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if another fluid is used. Do not overfill the system. NOTE: Although not required at specific intervals, the fluid level may be checked periodically. Check the fluid level anytime there is a system noise or fluid leak suspected. The power steering fluid level can be viewed through the side of the power steering fluid reservoir. Compare the fluid level to the markings on the side of the reservoir. When the fluid is at normal ambient temperature, approximately 21° C to 27° C (70° F to 80° F), the fluid level should read between the MAX. and MIN. markings. When the fluid is hot, fluid level is allowed to read up to the MAX. line. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 6622 Power Steering Fluid: Service and Repair POWER STEERING SYSTEM BLEEDING WARNING: The fluid level should be checked with engine off to prevent injury from moving components. CAUTION: Mopar(R) Power Steering Fluid + 4 or Mopar(R) ATF+4 Automatic Transmission Fluid is to be used in the power steering system. Both Fluids have the same material standard specifications (MS-9602). No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if another fluid is used. Do not overfill the system. CAUTION: If the air is not purged from the power steering system correctly, pump failure could result. NOTE: Be sure the vacuum tool used in the following procedure is clean and free of any fluids. 1. Check the fluid level. As measured on the side of the reservoir, the level should indicate between MAX and MIN when the fluid is at normal ambient temperature. Adjust the fluid level as necessary. 2. Tightly insert Power Steering Cap Adapter (4), Special Tool 9688, into the mouth of the reservoir (3). CAUTION: Failure to use a vacuum pump reservoir (1) may allow power steering fluid to be sucked into the hand vacuum pump. 3. Attach Hand Vacuum Pump (2), Special Tool C-4207 or equivalent, with reservoir (1) attached, to the Power Steering Cap Adapter (4). CAUTION: Do not run the engine while vacuum is applied to the power steering system. Damage to the power steering pump can occur. NOTE: When performing the following step make sure the vacuum level is maintained during the entire time period. 4. Using Hand Vacuum Pump (2), apply 68-85 kPa (20-25 in. Hg) of vacuum to the system for a minimum of three minutes. 5. Slowly release the vacuum and remove the special tools. 6. Adjust the fluid level as necessary. Refer to STEP 1. 7. Repeat STEP 1 through STEP 6 until the fluid no longer drops when vacuum is applied. 8. Start the engine and cycle the steering wheel lock-to-lock three times. NOTE: Do not hold the steering wheel at the stops. 9. Stop the engine and check for leaks at all connections. 10. Check for any signs of air in the reservoir and check the fluid level. If air is present, repeat the procedure as necessary. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Description and Operation Power Steering Fluid Cooler: Description and Operation DESCRIPTION The cooler is placed in series with the power steering fluid return hose, between the steering gear fluid outlet port and the fluid return hose leading to the power steering fluid reservoir. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair > Removal Power Steering Fluid Cooler: Service and Repair Removal REMOVAL NOTE: Before proceeding, refer to STEERING WARNING. 1. Siphon as much fluid as possible from the power steering fluid reservoir. 2. Raise and support the vehicle. 3. Remove the front fascia. 4. Remove the hose clamps (6) attaching the fluid return hose (7) to the power steering fluid cooler line. Separate the return hose from the cooler line (5). 5. Remove the two cooler mounting screws (4). 6. Remove the cooler tubes from the clips on the side of the frame rail. 7. Remove the cooler lines (5) from the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair > Removal > Page 6628 Power Steering Fluid Cooler: Service and Repair Installation INSTALLATION 1. Install the cooler tubes in the clips on the side of the frame rail. 2. Install the fluid cooler mounting screws (4) to the support. Tighten the screws to 8 Nm (71 in. lbs.). 3. Install the fluid return hose (7) on the power steering fluid cooler lines (5). Install the hose clamp (6) on the hose past the bead formed into the end of the cooler tube and secure in place. 4. Install the front fascia. 5. Lower the vehicle. 6. Fill and bleed the power steering system. 7. Check for leaks. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Description and Operation Power Steering Fluid Reservoir: Description and Operation DESCRIPTION The power steering fluid reservoir (5) is mounted above the right front inner fender well to a bracket (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair > Removal Power Steering Fluid Reservoir: Service and Repair Removal REMOVAL NOTE: Before proceeding, refer to STEERING WARNING. 1. Remove engine appearance cover. 2. Remove the fasteners securing the coolant recovery bottle to its mounts and move it away from the power steering fluid reservoir. It is not necessary to disconnect the coolant recovery bottle fluid lines. 3. Siphon as much fluid as possible from the power steering fluid reservoir (5). 4. Remove hose clamp securing cooler return hose (3) to fluid reservoir fitting. Slide the hose off the end of the reservoir fitting. 5. Remove hose clamp securing pump supply hose (4) to the fluid reservoir fitting. Slide the hose off the end of the reservoir fitting. 6. Remove the reservoir mounting screw (1) used to secure the reservoir in place. 7. Remove the reservoir (5). 8. Remove the plastic shield from the reservoir. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair > Removal > Page 6634 Power Steering Fluid Reservoir: Service and Repair Installation INSTALLATION 1. Install the plastic shield over the reservoir neck. 2. Attach the reservoir (5) to the strut tower bracket (2) using the mounting screw (1). Tighten mounting screw (1) to 12 Nm (106 in. lbs.). 3. Slide the pump supply hose (4) onto reservoir fitting. Expand hose clamp and slide it over hose on reservoir fitting. Secure clamp once it is past bead formed into fluid reservoir fitting. 4. Slide cooler return hose (3) onto reservoir fitting. Expand hose clamp and slide it over hose on reservoir fitting. Secure clamp once it is past bead formed into fluid reservoir fitting. 5. Install the coolant recovery bottle. 6. Fill and bleed the power steering system. 7. Check for leaks. 8. Install the engine appearance cover. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler Power Steering Line/Hose: Service and Repair Fluid Cooler Removal REMOVAL NOTE: Before proceeding, refer to STEERING WARNING. 1. Siphon as much fluid as possible from the power steering fluid reservoir. 2. Raise and support the vehicle. 3. Remove the front fascia. 4. Remove the hose clamps (6) attaching the fluid return hose (7) to the power steering fluid cooler line. Separate the return hose from the cooler line (5). 5. Remove the two cooler mounting screws (4). 6. Remove the cooler tubes from the clips on the side of the frame rail. 7. Remove the cooler lines (5) from the vehicle. Installation INSTALLATION 1. Install the cooler tubes in the clips on the side of the frame rail. 2. Install the fluid cooler mounting screws (4) to the support. Tighten the screws to 8 Nm (71 in. lbs.). 3. Install the fluid return hose (7) on the power steering fluid cooler lines (5). Install the hose clamp (6) on the hose past the bead formed into the end of the cooler tube and secure in place. 4. Install the front fascia. 5. Lower the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler > Page 6639 6. Fill and bleed the power steering system. 7. Check for leaks. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler > Page 6640 Power Steering Line/Hose: Service and Repair Hose-Pressure Removal GAS ENGINE NOTE: Before proceeding, refer to STEERING WARNING. 1. Siphon as much fluid as possible from the power steering fluid reservoir. 2. Remove the engine appearance cover. 3. Remove the pressure Hose (3) at the pump pressure port (5). 4. Remove the pressure hose routing bracket bolt (2) at the upper mount (8). 5. All except 2.4L Engine with All-Wheel-Drive - Remove the pressure hose routing clamp bolt (1) at the exhaust manifold. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler > Page 6641 6. 2.4L Engine with All-Wheel-Drive - Remove the pressure hose routing clamp bolt (1) at the exhaust manifold. 7. Raise and support the vehicle. 8. Remove the return hose (1) at the return tube (2). 9. Remove the return tube (1) at the steering gear (3). 10. Remove the pressure hose (2) at the steering gear (3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler > Page 6642 11. Remove the fasteners (1) securing the power steering hose routing clamps (2) to the crossmember. 12. Remove the power steering pressure hose from the vehicle. Installation GAS ENGINE CAUTION: Power steering fluid hoses must remain away from the exhaust system, driveshafts, vehicle components and any unfriendly surface that can possibly damage the hoses. 1. Using a lint free towel, wipe clean the open power steering hose end and the power steering pump port. Replace any used O-rings with new. Lubricate the O-ring with power steering fluid. 2. Install the power steering pressure hose into the engine compartment from below. 3. Install the fasteners (1) securing the power steering hose routing clamps (2) to the crossmember. Tighten the screws to 8 Nm (71 in. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler > Page 6643 4. Install the pressure hose (2) at the gear (3). Tighten the tube nut to 32 Nm (24 ft. lbs.). 5. Install the return tube (1) at the gear (3). Tighten the tube nut to 20 Nm (15 ft. lbs.). 6. Install the return hose (1) at the return tube (2). 7. Lower the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler > Page 6644 8. Install the pressure hose (3) at the pump pressure port (5). Tighten the tube nut to 32 Nm (24 ft. lbs.). 9. Install the pressure hose routing bracket bolt (2) to the upper mount (8). 10. All except 2.4L Engine with All-Wheel-Drive - Position the pressure hose routing clamp (2) at the exhaust manifold and install the mounting bolt (1). Tighten the bolt to 9 Nm (80 in. lbs.). 11. 2.4L Engine with All-Wheel-Drive - Position the pressure hose routing clamp (2) at the exhaust manifold and install the mounting bolt (1). Tighten the bolt to 9 Nm (80 in. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler > Page 6645 12. Fill and bleed the power steering system. 13. Check for leaks. 14. Install the engine appearance cover. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler > Page 6646 Power Steering Line/Hose: Service and Repair Return Hose Removal REMOVAL NOTE: Before proceeding, refer to STEERING WARNING. 1. Remove the engine appearance cover. 2. Remove the coolant recovery bottle. 3. Siphon as much fluid as possible from the power steering fluid reservoir. 4. Remove the power steering fluid reservoir. 5. Remove the windshield washer reservoir. 6. Remove the front fascia. 7. Remove the right headlamp. 8. Raise and support the vehicle. 9. Remove the return hose (1) at the return tube (2). 10. Remove the return hose routing clamp screw (2) securing the return hose (7) to the frame rail. 11. Lower the vehicle. 12. Remove the return hose routing clamp screw (1) securing the return hose (7) to the strut tower. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler > Page 6647 13. Remove the hose clamps (6) securing the return hose to the power steering reservoir and cooler. Slide the hose off the end of the cooler tube. 14. Remove the return hose from the vehicle. Installation INSTALLATION 1. Install the power steering return hose (7) into the engine compartment. 2. Install the return hose routing clamp screw (1) securing the return hose (7) to the strut tower. 3. Install the return hose onto the cooler tubes (5) and install the hose clamps (6). 4. Raise and support the vehicle. 5. Install the screw (2) securing the return hose to the frame rail. Tighten the screw to 19 Nm (14 ft. lbs.). 6. Install the return hose (1) at the return tube (2). 7. Lower the vehicle. 8. Install the right headlamp. 9. Install the front fascia. 10. Install the windshield washer reservoir. 11. Install the power steering fluid reservoir. 12. Install the coolant recovery bottle. 13. Fill and bleed the power steering system. 14. Check for leaks. 15. Install the engine appearance cover. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler > Page 6648 Power Steering Line/Hose: Service and Repair Hose-Supply Removal GAS ENGINE NOTE: Before proceeding, refer to STEERING WARNING. 1. Siphon as much fluid as possible from the power steering fluid reservoir. 2. Remove the clamp (2) securing the supply hose to the power steering pump (3) supply fitting, then remove the hose from the supply fitting. 3. Remove the hose clamp securing the supply hose (4) to the power steering fluid reservoir (5). Slide the hose off the end of the reservoir fitting and remove from vehicle. Installation Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler > Page 6649 GAS ENGINE 1. Slide hose clamps (2) onto both ends of the power steering fluid supply hose (1) far enough to clear the fittings on the reservoir and pump once the hose is installed. 2. Place the pump end of the supply hose (1) onto the pump (3) supply fitting. Expand the hose clamp (2) and slide it over the hose and pump supply fitting. Secure the clamp once it is past the bead formed into the fluid supply fitting. 3. Expand the hose clamp (4) at the fluid reservoir (5) and slide it over the hose and fitting. Secure the clamp once it is past the bead formed into the fluid reservoir fitting. 4. Perform the POWER STEERING PUMP BLEED PROCEDURE. 5. Check for leaks at all hose connections. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Description and Operation Power Steering Pump: Description and Operation DESCRIPTION Hydraulic pressure for operation of the power steering gear is provided by a droop-flow type power steering pump. The power steering pump is belt driven. The pulley (1) cannot be serviced separately. The power steering pump is serviced as a complete assembly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Description and Operation > Page 6653 Power Steering Pump: Testing and Inspection POWER STEERING PUMP AND HOSES NOTE: This information is designed to be used in conjunction with the diagnostic charts at the beginning of the Steering section. CHECKING FOR WEAR OF POWER STEERING PUMP INTERNAL COMPONENTS 1. Place gear selector in PARK (or NEUTRAL) with wheels chalked. 2. With the engine idling, have a helper turn the steering wheel. 3. Using an electronic listening tool, determine if noise is coming from the pump. 4. Increase the engine speed and have a helper turn the steering wheel. Does the noise change with load? 5. Replace the power steering pump if excessive noise is present. CHECKING FOR POWER STEERING HOSES TOUCHING BODY OR FRAME OF VEHICLE Check hoses and hose tubes as following: - Inspect hoses and hose tubes for witness marks. If witness marks are present, adjust hose(s) to the proper position by loosening, repositioning and tightening attachments to the specified torque. Do not bend tubing to adjust. Replace the hose assembly if damaged. - Check fastener torque of hose mounting brackets and tube nuts. - Have a helper bump the steering gear off of the stops to induce pressure fluctuations which may move the hose. If hose contact is made, adjust hose(s) to the proper position by loosening, repositioning and tightening attachments to the specified torque. Do not bend tubing to adjust. Replace the hose assembly if damaged. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal Power Steering Pump: Service and Repair Removal GAS ENGINE NOTE: Before proceeding, refer to STEERING WARNING. 1. Siphon as much fluid as possible from the power steering fluid reservoir. 2. Remove the engine appearance cover. 3. Remove the pressure hose routing bracket bolt (2) at the upper mount (8). 4. Remove the pressure hose (3) at the pump pressure port (5). 5. Remove the hose clamp (2) securing the supply hose (1) at the pump. 6. Remove the supply hose (1) from the pump (3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal > Page 6656 7. Remove the drive belt (2). 8. Remove the three pump mounting bolts (1) through the pulley (3) openings. 9. Remove the power steering pump. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal > Page 6657 Power Steering Pump: Service and Repair Installation GAS ENGINE 1. Using a lint free towel, wipe clean the open power steering pressure hose end and the power steering pump port. Replace any used O-rings with new. Lubricate the O-ring with clean power steering fluid. 2. Place the pump in mounting position. Install the three bolts (1) through the pulley (3) openings. Tighten the mounting bolts (1) to 26 Nm (19 ft. lbs.). 3. Install the drive belt (2). 4. Install the supply hose (1) at the pump (3). 5. Clamp the hose clamp (2) securing the supply hose (1) to the pump. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal > Page 6658 6. Install the pressure hose (3) at the pump pressure port (5). Tighten the tube nut to 32 Nm (24 ft. lbs.). 7. Install the pressure hose routing bracket bolt (2) to the upper mount (8). 8. Fill and bleed the power steering system. 9. Check for leaks. 10. Install the engine appearance cover. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations Steering Control Module: Locations Component ID: 162 Component : MODULE-STEERING CONTROL Connector: Name : MODULE-STEERING CONTROL C1 Color : WHITE # of pins : 4 Pin Description Circuit 1 GROUND Z937 20BK/YL Pin Description Circuit 1 GROUND Z936 20BK/LB 2 FUSED B(+) (I.O.D.) A411 20RD/LG 3 LIN BUS D506 20WT/DG 4 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY Component Location - 28 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations > Page 6662 Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations > Page 6663 Connector: Name : MODULE-STEERING CONTROL C2 Color : WHITE # of pins : 6 Pin Description Circuit 1 RADIO CONTROL MUX X20 20GY/WT 2 RADIO CONTROL RETURN Y13 20DG/RD 3 HORN SWITCH SENSE X3 20DG/VT 4 S/C SIGNAL 2 V72 20OR/VT 5 S/C SWITCH GROUND V937 20VT/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations > Page 6664 6 S/C SIGNAL 1 V71 20VT/OR Component Location - 28 Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations > Page 6665 Connector: Name : MODULE-STEERING CONTROL C4 Color : WHITE # of pins : 4 Pin Description Circuit 1 DRIVER SQUIB 2 LINE 1 R63 18LG/BK 2 DRIVER SQUIB 2 LINE 2 R61 18LG/VT 3 DRIVER SQUIB 1 LINE 1 R45 18LG/RD 4 DRIVER SQUIB 1 LINE 2 R43 18LG/BR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations > Page 6666 Component Location - 28 Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations > Page 6667 Connector: Name : MODULE-STEERING CONTROL C5 Color : WHITE # of pins : 6 Pin Description Circuit 1 RADIO CONTROL MUX X20 20GY Pin Description Circuit 1 RADIO CONTROL MUX X20 20GY 2 RADIO CONTROL RETURN Y13 20BK Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations > Page 6668 2 RADIO CONTROL RETURN Y13 20BK 3 HORN SWITCH SENSE X3 20DB 4 S/C SIGNAL 2 V72 20PK 5 S/C SIGNAL 1 V71 20VT 6 S/C SWITCH GROUND V937 20YL Component Location - 28 Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations > Page 6669 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations > Page 6670 Steering Control Module: Diagrams Component ID: 162 Component : MODULE-STEERING CONTROL Connector: Name : MODULE-STEERING CONTROL C1 Color : WHITE # of pins : 4 Pin Description Circuit 1 GROUND Z937 20BK/YL Pin Description Circuit 1 GROUND Z936 20BK/LB 2 FUSED B(+) (I.O.D.) A411 20RD/LG 3 LIN BUS D506 20WT/DG 4 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY Component Location - 28 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations > Page 6671 Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations > Page 6672 Connector: Name : MODULE-STEERING CONTROL C2 Color : WHITE # of pins : 6 Pin Description Circuit 1 RADIO CONTROL MUX X20 20GY/WT 2 RADIO CONTROL RETURN Y13 20DG/RD 3 HORN SWITCH SENSE X3 20DG/VT 4 S/C SIGNAL 2 V72 20OR/VT 5 S/C SWITCH GROUND V937 20VT/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations > Page 6673 6 S/C SIGNAL 1 V71 20VT/OR Component Location - 28 Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations > Page 6674 Connector: Name : MODULE-STEERING CONTROL C4 Color : WHITE # of pins : 4 Pin Description Circuit 1 DRIVER SQUIB 2 LINE 1 R63 18LG/BK 2 DRIVER SQUIB 2 LINE 2 R61 18LG/VT 3 DRIVER SQUIB 1 LINE 1 R45 18LG/RD 4 DRIVER SQUIB 1 LINE 2 R43 18LG/BR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations > Page 6675 Component Location - 28 Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations > Page 6676 Connector: Name : MODULE-STEERING CONTROL C5 Color : WHITE # of pins : 6 Pin Description Circuit 1 RADIO CONTROL MUX X20 20GY Pin Description Circuit 1 RADIO CONTROL MUX X20 20GY 2 RADIO CONTROL RETURN Y13 20BK Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations > Page 6677 2 RADIO CONTROL RETURN Y13 20BK 3 HORN SWITCH SENSE X3 20DB 4 S/C SIGNAL 2 V72 20PK 5 S/C SIGNAL 1 V71 20VT 6 S/C SWITCH GROUND V937 20YL Component Location - 28 Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations > Page 6678 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Column Control Module > Component Information > Description and Operation > Description Steering Column Control Module: Description and Operation Description DESCRIPTION This vehicle is equipped with a Steering Column Control Module (SCCM) The SCCM is secured near the top of the steering column below the steering wheel and is completely concealed beneath the steering column shrouds. It is installed as a modular unit that supports the left (lighting) multi-function switch (1) and right (wiper) multi-function switch (6). The controls for each of these switches extend through appropriate clearance holes provided in the steering column shrouds. The microprocessor-based Steering Control Module (SCM) (2) utilizes integrated circuitry and information carried on the Controller Area Network (CAN) data bus along with several hard wired analog and multiplexed inputs to monitor both the right and left multi-function switches. The SCCM uses a Local Interconnect Network (LIN) data bus for exterior lighting and wiper functions. The LIN data is sent to the Cab Compartment Node (CCN) and the CCN then sends it out on the CAN data bus. The SCCM is available for service replacement as a unit or each individual component: - Clockspring (with integral Steering Angle Sensor if equipped) - Left Multi-Function Switch - Right Multi-Function Switch Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Column Control Module > Component Information > Description and Operation > Description > Page 6684 Steering Column Control Module: Description and Operation Operation OPERATION The Steering Control Module (SCM) communicates over the Local Interconnect Network (LIN) data bus with other electronic modules in the vehicle and/or a diagnostic scan tool. The horn switch circuits pass through the clockspring to the Cab Compartment Node (CCN) and the CCN sends a CAN message to the Totally Integrated Power Module (TIPM) to control the horn. The CCN stores Diagnostic Trouble Codes (DTC's) for the SCM. The right (wiper) multi-function switch has several inputs to the CCN. The SCM is connected to a fused B(+) circuit and receives a path to ground at all times. These connections allow it to remain functional regardless of the ignition switch position. The driver airbag squib circuits of the clockspring, the horn, and the speed control switch circuits pass through the SCM, but the SCM does not monitor, and has no control outputs related to these circuits. Any other input to the SCM that would cause a vehicle system to function but does not require that the ignition switch be in the On position, such as turning on the lights or sounding the horn, prompts the SCM to wake up and transmit on the CAN data bus. The most reliable, efficient, and accurate means to diagnose the SCM, the CAN data bus, the hard wired inputs or the electronic communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. The integral SCM is not available for separate service replacement. If found inoperative or defective, the entire left (lighting) multi-function switch must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Column Control Module > Component Information > Service and Repair > Removal Steering Column Control Module: Service and Repair Removal REMOVAL SCCM 1. Place the front road wheels in the STRAIGHT-AHEAD position. 2. Open hood. 3. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. 4. Remove steering wheel. 5. Remove upper and lower steering column shrouds to gain access to the Steering Column Control Module (SCCM). 6. Lock the clockspring rotor in the center position as follows: Insert a grenade pin through the hole in the rotor at the 10 o'clock position. 7. Remove the three screws (1) to the Steering Column Control Module (SCCM) (3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Column Control Module > Component Information > Service and Repair > Removal > Page 6687 8. Disconnect the electrical connectors (2) between the SCCM (1) and the instrument panel wiring harness at the base of the SCCM and remove from column. NOTE: If only removing the SCCM from column, there is no need to continue to next step. DISASSEMBLY 1. Remove the left multi-function switch stalk retaining screw (2). 2. Pull the left stalk out of the SCCM. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Column Control Module > Component Information > Service and Repair > Removal > Page 6688 3. Disconnect the left stalk electrical connector. 4. Separate the left switch from the SCCM. 5. Remove the one right multi-function switch retaining screw. 6. Pull right switch out of SCCM. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Column Control Module > Component Information > Service and Repair > Removal > Page 6689 7. Disconnect the right switch electrical connector. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Column Control Module > Component Information > Service and Repair > Removal > Page 6690 Steering Column Control Module: Service and Repair Installation INSTALLATION NOTE: If SCCM is already assembled and needs to be installed, bypass ASSEMBLY and proceed with SCCM STEP 1. ASSEMBLY 1. Connect the right stalk electrical connector. 2. Slide the right stalk into the groove and install the one retaining screw. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Column Control Module > Component Information > Service and Repair > Removal > Page 6691 3. Connect the left stalk switch electrical connector. 4. Install the left stalk switch retaining screw. SCCM Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Column Control Module > Component Information > Service and Repair > Removal > Page 6692 1. Position the SCCM (3) over the steering column shaft (2). 2. Install the three screws (1). 3. Connect the electrical connectors (2) to the instrument panel harness, ensure wiring is properly routed. Then check that the connectors, locking tabs are properly engaged. 4. Install steering column shrouds. Be sure all wires are inside of shrouds. 5. Install steering wheel ensuring the flats on hub align with the clockspring. Pull the airbag leads through the larger slot. Ensure leads do not get pinched under the steering wheel. NOTE: There is a small wire harness in the steering wheel and it contains the horn circuits and speed control circuits. 6. Connect the speed control and horn wire connector into the clockspring. 7. Pull the grenade pin out of the clockspring. 8. Install the driver airbag. WARNING: Do not connect the battery negative cable. Personal injury or death may result if the system test is not performed first. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations Steering Control Module: Locations Component ID: 162 Component : MODULE-STEERING CONTROL Connector: Name : MODULE-STEERING CONTROL C1 Color : WHITE # of pins : 4 Pin Description Circuit 1 GROUND Z937 20BK/YL Pin Description Circuit 1 GROUND Z936 20BK/LB 2 FUSED B(+) (I.O.D.) A411 20RD/LG 3 LIN BUS D506 20WT/DG 4 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY Component Location - 28 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 6696 Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 6697 Connector: Name : MODULE-STEERING CONTROL C2 Color : WHITE # of pins : 6 Pin Description Circuit 1 RADIO CONTROL MUX X20 20GY/WT 2 RADIO CONTROL RETURN Y13 20DG/RD 3 HORN SWITCH SENSE X3 20DG/VT 4 S/C SIGNAL 2 V72 20OR/VT 5 S/C SWITCH GROUND V937 20VT/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 6698 6 S/C SIGNAL 1 V71 20VT/OR Component Location - 28 Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 6699 Connector: Name : MODULE-STEERING CONTROL C4 Color : WHITE # of pins : 4 Pin Description Circuit 1 DRIVER SQUIB 2 LINE 1 R63 18LG/BK 2 DRIVER SQUIB 2 LINE 2 R61 18LG/VT 3 DRIVER SQUIB 1 LINE 1 R45 18LG/RD 4 DRIVER SQUIB 1 LINE 2 R43 18LG/BR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 6700 Component Location - 28 Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 6701 Connector: Name : MODULE-STEERING CONTROL C5 Color : WHITE # of pins : 6 Pin Description Circuit 1 RADIO CONTROL MUX X20 20GY Pin Description Circuit 1 RADIO CONTROL MUX X20 20GY 2 RADIO CONTROL RETURN Y13 20BK Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 6702 2 RADIO CONTROL RETURN Y13 20BK 3 HORN SWITCH SENSE X3 20DB 4 S/C SIGNAL 2 V72 20PK 5 S/C SIGNAL 1 V71 20VT 6 S/C SWITCH GROUND V937 20YL Component Location - 28 Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 6703 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 6704 Steering Control Module: Diagrams Component ID: 162 Component : MODULE-STEERING CONTROL Connector: Name : MODULE-STEERING CONTROL C1 Color : WHITE # of pins : 4 Pin Description Circuit 1 GROUND Z937 20BK/YL Pin Description Circuit 1 GROUND Z936 20BK/LB 2 FUSED B(+) (I.O.D.) A411 20RD/LG 3 LIN BUS D506 20WT/DG 4 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY Component Location - 28 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 6705 Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 6706 Connector: Name : MODULE-STEERING CONTROL C2 Color : WHITE # of pins : 6 Pin Description Circuit 1 RADIO CONTROL MUX X20 20GY/WT 2 RADIO CONTROL RETURN Y13 20DG/RD 3 HORN SWITCH SENSE X3 20DG/VT 4 S/C SIGNAL 2 V72 20OR/VT 5 S/C SWITCH GROUND V937 20VT/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 6707 6 S/C SIGNAL 1 V71 20VT/OR Component Location - 28 Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 6708 Connector: Name : MODULE-STEERING CONTROL C4 Color : WHITE # of pins : 4 Pin Description Circuit 1 DRIVER SQUIB 2 LINE 1 R63 18LG/BK 2 DRIVER SQUIB 2 LINE 2 R61 18LG/VT 3 DRIVER SQUIB 1 LINE 1 R45 18LG/RD 4 DRIVER SQUIB 1 LINE 2 R43 18LG/BR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 6709 Component Location - 28 Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 6710 Connector: Name : MODULE-STEERING CONTROL C5 Color : WHITE # of pins : 6 Pin Description Circuit 1 RADIO CONTROL MUX X20 20GY Pin Description Circuit 1 RADIO CONTROL MUX X20 20GY 2 RADIO CONTROL RETURN Y13 20BK Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 6711 2 RADIO CONTROL RETURN Y13 20BK 3 HORN SWITCH SENSE X3 20DB 4 S/C SIGNAL 2 V72 20PK 5 S/C SIGNAL 1 V71 20VT 6 S/C SWITCH GROUND V937 20YL Component Location - 28 Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 6712 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Description Steering Mounted Controls Communication Module: Description and Operation Description DESCRIPTION This vehicle is equipped with a Steering Column Control Module (SCCM) The SCCM is secured near the top of the steering column below the steering wheel and is completely concealed beneath the steering column shrouds. It is installed as a modular unit that supports the left (lighting) multi-function switch (1) and right (wiper) multi-function switch (6). The controls for each of these switches extend through appropriate clearance holes provided in the steering column shrouds. The microprocessor-based Steering Control Module (SCM) (2) utilizes integrated circuitry and information carried on the Controller Area Network (CAN) data bus along with several hard wired analog and multiplexed inputs to monitor both the right and left multi-function switches. The SCCM uses a Local Interconnect Network (LIN) data bus for exterior lighting and wiper functions. The LIN data is sent to the Cab Compartment Node (CCN) and the CCN then sends it out on the CAN data bus. The SCCM is available for service replacement as a unit or each individual component: - Clockspring (with integral Steering Angle Sensor if equipped) - Left Multi-Function Switch - Right Multi-Function Switch Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Description > Page 6717 Steering Mounted Controls Communication Module: Description and Operation Operation OPERATION The Steering Control Module (SCM) communicates over the Local Interconnect Network (LIN) data bus with other electronic modules in the vehicle and/or a diagnostic scan tool. The horn switch circuits pass through the clockspring to the Cab Compartment Node (CCN) and the CCN sends a CAN message to the Totally Integrated Power Module (TIPM) to control the horn. The CCN stores Diagnostic Trouble Codes (DTC's) for the SCM. The right (wiper) multi-function switch has several inputs to the CCN. The SCM is connected to a fused B(+) circuit and receives a path to ground at all times. These connections allow it to remain functional regardless of the ignition switch position. The driver airbag squib circuits of the clockspring, the horn, and the speed control switch circuits pass through the SCM, but the SCM does not monitor, and has no control outputs related to these circuits. Any other input to the SCM that would cause a vehicle system to function but does not require that the ignition switch be in the On position, such as turning on the lights or sounding the horn, prompts the SCM to wake up and transmit on the CAN data bus. The most reliable, efficient, and accurate means to diagnose the SCM, the CAN data bus, the hard wired inputs or the electronic communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. The integral SCM is not available for separate service replacement. If found inoperative or defective, the entire left (lighting) multi-function switch must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Technical Service Bulletins > Steering - ESP Lamp On Possible DTC C121A/C2205 Steering Angle Sensor: Technical Service Bulletins Steering - ESP Lamp On Possible DTC C121A/C2205 NUMBER: 08-010-07 GROUP: Vehicle Performance DATE: May 17, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: DTC's C121A / C2205 - Steering Angle Sensor - Not Initialized / Internal OVERVIEW: This bulletin involves selectively erasing and reprogramming the Steering Angle Sensor (SAS) with new software. MODELS: 2007 (JK) Wrangler 2007 (JS) Sebring 2007 (KA) Nitro 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to vehicles built on or before April 12, 2007 (MDH 0412XX). SYMPTOM/CONDITION: The vehicle operator may experience an illumination of the Electronic Stability Program (ESP) lamp on the vehicle instrument cluster. The ESP lamp illumination may be due to the following Diagnostic Trouble Codes (DTC's): C121A - Steering Angle Sensor Not Initialized C2205 - Steering Angle Sensor Internal This condition, and DTC's, may be intermittent. If the above DTC's occur during a drive cycle, then the ESP lamp will remain illuminated until the end of that drive cycle (key off). DIAGNOSIS: Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Technical Service Bulletins > Steering - ESP Lamp On Possible DTC C121A/C2205 > Page 6723 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 7.04 SPI or higher. The software release level is visible in the blue header at the top of the StarSCAN® screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. For instruction on setting up your StarSCAN® for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU (SAS) part number. Using the StarSCAN(R) at the "Home screen: a. Select "ECU View" b. Touch the screen to highlight the ECU (SAS) in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Technical Service Bulletins > Steering - ESP Lamp On Possible DTC C121A/C2205 > Page 6724 k. When the update is complete, select "OK". NOTE: Due to the ECU (SAS) programming procedure, a DTC may be set in other electronic modules within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Technical Service Bulletins > Steering - ESP Lamp On Possible DTC C121A/C2205 Steering Angle Sensor: Technical Service Bulletins Steering - ESP Lamp On Possible DTC C121A/C2205 NUMBER: 08-010-07 GROUP: Vehicle Performance DATE: May 17, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: DTC's C121A / C2205 - Steering Angle Sensor - Not Initialized / Internal OVERVIEW: This bulletin involves selectively erasing and reprogramming the Steering Angle Sensor (SAS) with new software. MODELS: 2007 (JK) Wrangler 2007 (JS) Sebring 2007 (KA) Nitro 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to vehicles built on or before April 12, 2007 (MDH 0412XX). SYMPTOM/CONDITION: The vehicle operator may experience an illumination of the Electronic Stability Program (ESP) lamp on the vehicle instrument cluster. The ESP lamp illumination may be due to the following Diagnostic Trouble Codes (DTC's): C121A - Steering Angle Sensor Not Initialized C2205 - Steering Angle Sensor Internal This condition, and DTC's, may be intermittent. If the above DTC's occur during a drive cycle, then the ESP lamp will remain illuminated until the end of that drive cycle (key off). DIAGNOSIS: Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Technical Service Bulletins > Steering - ESP Lamp On Possible DTC C121A/C2205 > Page 6729 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 7.04 SPI or higher. The software release level is visible in the blue header at the top of the StarSCAN® screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. For instruction on setting up your StarSCAN® for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU (SAS) part number. Using the StarSCAN(R) at the "Home screen: a. Select "ECU View" b. Touch the screen to highlight the ECU (SAS) in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Technical Service Bulletins > Steering - ESP Lamp On Possible DTC C121A/C2205 > Page 6730 k. When the update is complete, select "OK". NOTE: Due to the ECU (SAS) programming procedure, a DTC may be set in other electronic modules within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Control Module > Component Information > Description and Operation > Description Steering Column Control Module: Description and Operation Description DESCRIPTION This vehicle is equipped with a Steering Column Control Module (SCCM) The SCCM is secured near the top of the steering column below the steering wheel and is completely concealed beneath the steering column shrouds. It is installed as a modular unit that supports the left (lighting) multi-function switch (1) and right (wiper) multi-function switch (6). The controls for each of these switches extend through appropriate clearance holes provided in the steering column shrouds. The microprocessor-based Steering Control Module (SCM) (2) utilizes integrated circuitry and information carried on the Controller Area Network (CAN) data bus along with several hard wired analog and multiplexed inputs to monitor both the right and left multi-function switches. The SCCM uses a Local Interconnect Network (LIN) data bus for exterior lighting and wiper functions. The LIN data is sent to the Cab Compartment Node (CCN) and the CCN then sends it out on the CAN data bus. The SCCM is available for service replacement as a unit or each individual component: - Clockspring (with integral Steering Angle Sensor if equipped) - Left Multi-Function Switch - Right Multi-Function Switch Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Control Module > Component Information > Description and Operation > Description > Page 6736 Steering Column Control Module: Description and Operation Operation OPERATION The Steering Control Module (SCM) communicates over the Local Interconnect Network (LIN) data bus with other electronic modules in the vehicle and/or a diagnostic scan tool. The horn switch circuits pass through the clockspring to the Cab Compartment Node (CCN) and the CCN sends a CAN message to the Totally Integrated Power Module (TIPM) to control the horn. The CCN stores Diagnostic Trouble Codes (DTC's) for the SCM. The right (wiper) multi-function switch has several inputs to the CCN. The SCM is connected to a fused B(+) circuit and receives a path to ground at all times. These connections allow it to remain functional regardless of the ignition switch position. The driver airbag squib circuits of the clockspring, the horn, and the speed control switch circuits pass through the SCM, but the SCM does not monitor, and has no control outputs related to these circuits. Any other input to the SCM that would cause a vehicle system to function but does not require that the ignition switch be in the On position, such as turning on the lights or sounding the horn, prompts the SCM to wake up and transmit on the CAN data bus. The most reliable, efficient, and accurate means to diagnose the SCM, the CAN data bus, the hard wired inputs or the electronic communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. The integral SCM is not available for separate service replacement. If found inoperative or defective, the entire left (lighting) multi-function switch must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Control Module > Component Information > Service and Repair > Removal Steering Column Control Module: Service and Repair Removal REMOVAL SCCM 1. Place the front road wheels in the STRAIGHT-AHEAD position. 2. Open hood. 3. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. 4. Remove steering wheel. 5. Remove upper and lower steering column shrouds to gain access to the Steering Column Control Module (SCCM). 6. Lock the clockspring rotor in the center position as follows: Insert a grenade pin through the hole in the rotor at the 10 o'clock position. 7. Remove the three screws (1) to the Steering Column Control Module (SCCM) (3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Control Module > Component Information > Service and Repair > Removal > Page 6739 8. Disconnect the electrical connectors (2) between the SCCM (1) and the instrument panel wiring harness at the base of the SCCM and remove from column. NOTE: If only removing the SCCM from column, there is no need to continue to next step. DISASSEMBLY 1. Remove the left multi-function switch stalk retaining screw (2). 2. Pull the left stalk out of the SCCM. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Control Module > Component Information > Service and Repair > Removal > Page 6740 3. Disconnect the left stalk electrical connector. 4. Separate the left switch from the SCCM. 5. Remove the one right multi-function switch retaining screw. 6. Pull right switch out of SCCM. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Control Module > Component Information > Service and Repair > Removal > Page 6741 7. Disconnect the right switch electrical connector. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Control Module > Component Information > Service and Repair > Removal > Page 6742 Steering Column Control Module: Service and Repair Installation INSTALLATION NOTE: If SCCM is already assembled and needs to be installed, bypass ASSEMBLY and proceed with SCCM STEP 1. ASSEMBLY 1. Connect the right stalk electrical connector. 2. Slide the right stalk into the groove and install the one retaining screw. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Control Module > Component Information > Service and Repair > Removal > Page 6743 3. Connect the left stalk switch electrical connector. 4. Install the left stalk switch retaining screw. SCCM Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Control Module > Component Information > Service and Repair > Removal > Page 6744 1. Position the SCCM (3) over the steering column shaft (2). 2. Install the three screws (1). 3. Connect the electrical connectors (2) to the instrument panel harness, ensure wiring is properly routed. Then check that the connectors, locking tabs are properly engaged. 4. Install steering column shrouds. Be sure all wires are inside of shrouds. 5. Install steering wheel ensuring the flats on hub align with the clockspring. Pull the airbag leads through the larger slot. Ensure leads do not get pinched under the steering wheel. NOTE: There is a small wire harness in the steering wheel and it contains the horn circuits and speed control circuits. 6. Connect the speed control and horn wire connector into the clockspring. 7. Pull the grenade pin out of the clockspring. 8. Install the driver airbag. WARNING: Do not connect the battery negative cable. Personal injury or death may result if the system test is not performed first. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Cover-Steering Column Opening Steering Column Cover: Service and Repair Cover-Steering Column Opening Removal REMOVAL 1. Using trim stick C-4755, disengage clips on column cover top edge. 2. Remove from vehicle. Installation INSTALLATION 1. Align top of column cover tabs with instrument panel. 2. Hand tap top of column cover ensuring column cover tabs seat. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Cover-Steering Column Opening > Page 6749 Steering Column Cover: Service and Repair Upper And Lower Steering Bezel Removal REMOVAL 1. Remove the two screws (4) attaching the upper shroud (1) to the lower shroud (2). After removing the screws, unclip the shrouds from each other by applying hand pressure along the seams where the shrouds connect on the sides, then remove the upper shroud and lower steering column cover . Installation INSTALLATION 1. Position the column tilt at the full-downward position and lock it in place. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Cover-Steering Column Opening > Page 6750 2. Install the upper shroud over the lower shroud, clipping the shrouds to one another. 3. Install the two screws (4) attaching the upper shroud (1) to the lower shroud (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Cover-Steering Column Opening > Page 6751 Steering Column Cover: Service and Repair Shroud - Lower Removal REMOVAL Special Tools 1. Remove the screws (2) from the bottom of the steering column opening cover (1). 2. Using Trim Stick C-4755 separate the steering column opening cover (1) and remove. 3. Position the column tilt at the full-downward position. 4. Remove the two screws (4) attaching the upper shroud (1) to the lower shroud (2). After removing the screws, unclip the shrouds from each other by applying hand pressure along the seams where the shrouds connect on the sides, then remove the upper shroud. 5. Push the tilt lever (5) downward. 6. Remove the screw (3) attaching the lower shroud (2) to the steering column (6). Remove the lower shroud. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Cover-Steering Column Opening > Page 6752 Installation INSTALLATION 1. Push the tilt lever (5) downward. 2. Install the lower shroud (2) over the tilt lever and onto the column. 3. Position the column tilt (5) at the full-upward position. 4. Push the tilt lever (5) upward, locking it in place. 5. Install the screw (3) attaching the lower shroud (2) to the steering column (6). 6. Position the column tilt at the full-downward position and lock it in place. 7. Install the upper shroud overthe lower shroud, clipping the shrouds to one another. 8. Install the two screws (4) attaching the upper shroud (1) to the lower shroud (2). 9. Place the steering column opening cover (1) in place and seat the clips fully. 10. Install the two screws (2) and tighten until secure. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Cover-Steering Column Opening > Page 6753 Steering Column Cover: Service and Repair Shroud - Upper Removal REMOVAL 1. Position the column tilt at the full-downward position. 2. Remove the two screws (4) attaching the upper shroud (1) to the lower shroud (2). After removing the screws, unclip the shrouds from each other by applying hand pressure along the seams where the shrouds connect on the sides, then remove the upper shroud. Installation INSTALLATION 1. Position the column tilt at the full-downward position and lock it in place. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Cover-Steering Column Opening > Page 6754 2. Install the upper shroud over the lower shroud, clipping the shrouds to one another. 3. Install the two screws (4) attaching the upper shroud (1) to the lower shroud (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Technical Service Bulletins > Customer Interest for Steering Column Lock: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition Steering Column Lock: Customer Interest Antitheft System - Engine No Crank/No Start Condition NUMBER: 08-007-08 REV. A GROUP: Electrical DATE: July 04,2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-007-08, DATED MARCH 04, 2008. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. DO NOT ORDER PART NUMBER 05026070AP UNTIL JULY 21, 2008. ALL OTHER PART NUMBERS ARE AVAILABLE NOW. SUBJECT: No Engine Crank Or No Engine Start Due To Electronic Lockup Of The WCM / SKREEM OVERVIEW: This bulletin involves the replacement of the Wireless Control Module (WCM), and if equipped, the replacement of the Electric Steering Column Lock (ELV). The WCM is also referred to as the Sentry Key Remote Entry Module (SKREEM). MODELS: 2007 - 2008 (DR/DH/D1/DC/DM) Ram Truck (1500/2500/3500/4500/5500) 2007 - 2008 (JK) Wrangler 2007 - 2008 (J1) Sebring (China) 2007 - 2008 (JS) Avenger/Sebring 2007 - 2008 (KA) Nitro 2008 (KK) Liberty/Cherokee 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber 2006 - 2008 (PT) Chrysler PT Cruiser NOTE: This bulletin applies to vehicles built on or before May 05, 2008 (MDH 0505XX). SYMPTOM/CONDITION: The customer will experience a no engine crank AND a no engine start condition. Also, the remote keyless entry (RKE) system will not operate. This condition may be due to an electrostatic discharge (ESD) from the ignition key into the Wireless Control Module (WCM), causing the WCM to electronically lockup. This condition may occur more frequently in dry and/or cold weather conditions where a sufficient electrostatic charge is more easily produced. This condition is corrected by the replacement of the WCM. DIAGNOSIS: 1. With the condition present (i.e. the vehicle in the no crank / no start condition), connect the StarSCAN(R) scan tool to the vehicle. 2. Turn the ignition switch to the "ON position, and power up the StarSCAN(R). 3. If the WCM is electronically locked up, the StarSCAN(R) will display the WCM as being "off bus". 4. If the no crank / no start condition is present, and the WCM is "off bus", then reset the WCM by temporarily removing the IOD fuse (with the key out of the ignition switch), wait for 10 seconds and then reinstall the IOD fuse. 5. With the IOD fuse reset having been performed, verify that the vehicle will now crank, start, and run. 6. If the condition is temporarily corrected by performing the above steps, and if the part number of the WCM is earlier than the part number of the WCM listed in the part reference table in the Service Bulletin Parts Required Section below, then perform the Repair Procedure. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Technical Service Bulletins > Customer Interest for Steering Column Lock: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 6763 PARTS REQUIRED: NOTE: The part numbers listed in the following part reference table are to be used as A GUIDE to help determine if the WCM, that is currently in the vehicle, may require replacement. If it is determined that the WCM requires replacement, then ALWAYS REFER TO THE PARTS MANUAL to determine the correct WCM for the specific vehicle in question. In some earlier model years, the WCM may rule (supersede) to one of the part numbers listed in the table. ALWAYS REFER TO THE PARTS MANUAL (not the part reference table) to determine the correct part number ruling (supercedence / substitution). MAKE CERTAIN THAT THE CORRECT WCM IS ORDERED THE FIRST TIME FOR THE SPECIFIC VEHICLE IN QUESTION. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Technical Service Bulletins > Customer Interest for Steering Column Lock: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 6764 REPAIR PROCEDURE: NOTE: If the vehicle (a JS model vehicle in certain International markets) is equipped with an Electric Steering Column Lock (ELV), then the WCM and the ELV must be replaced. Replace the WCM and then the ELV. Next program the WCM and at least one (1) ignition key BEFORE programming the ELV. IMPORTANT: Not following this repair process correctly will cause the new ELV to fail. NOTE: Insert the ignition key into the ignition lock cylinder. This will move the shaft lock module locking bolt to the unlocked position. LEAVE the key in the lock cylinder while the shaft lock module is being removed. 1. If vehicle is equipped with a Steering Shaft Lock Module (JS - Avenger I Stratus - some International Markets), then the Shaft Lock Module will require replacement. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Security Information > Module, Shaft Lock > Removal and Installation. NOTE: The shaft lock module cannot be removed from the steering column while the locking bolt is in the locked position without irreversibly damaging the column. Before attempting service, the ignition key must have been inserted into the ignition lock cylinder. Then rotate the steering wheel from side to side. If the steering wheel can be rotated, the locking bolt is in the unlocked position. Leave the key in the ignition lock cylinder until shaft lock module removal has been completed. If the steering wheel cannot be rotated, test and repair the wiring circuits between the module and the ignition switch as required. If no problem is found in these circuits, the module has failed with the locking bolt in the locked position and both the module and the steering column must be replaced with new units. 2. Replace the WCM/SKREEM. Refer to TechCONNECT for detailed service information. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Service Information > Module, Sentry Key Remote Entry > Removal and Installation. NOTE: Obtain the vehicle PIN number prior to programming WCM/SKREEM or ELV. NOTE: If during the following steps the PIN number is properly entered but is rejected, then reenter the PIN number again until it is accepted. 3. After both the WCM/SKREEM and the ELV (if equipped) have been replaced, Program the WCM/SKREEM as follows: a. Turn the ignition key to the ON position, (Engine Off) b. Connect the scan tool (StarSCAN(R)) to the data link connector and turn the ignition to the RUN position, (engine off). c. Select "ECU View." d. Scroll down and select "WCM" in the list of modules. e. Select "Misc. Functions." f. Scroll to "WCM Replaced." g. Press "Start". h. Press "Next". i. Select "Show Keyboard". j. Enter the vehicle PIN number. k. Select "Next". l. Verify PIN is correct. m. Select "Next". n. Follow on-screen prompts to complete WCM function programing for Tire Pressure Monitoring (TPM) and so on. 0. Turn the ignition key to the OFF position. Wait 30 seconds. p. Turn the ignition key to the ON position, (Engine Off) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Technical Service Bulletins > Customer Interest for Steering Column Lock: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 6765 q. Select "ECU View". r. Scroll down and select "WCM" in the list of modules. s. Select "Misc. Functions." t. Select "Program Ign. Keys" and follow on-screen prompts. u. Select "Complete". v. Verify ignition key will start vehicle and the Remote Keyless Entry (RKE) functions operate. CAUTION: If the vehicle is equipped with a Shaft Lock Module (used in some International Markets on JS model vehicles), then at least one (1 ignition key must have been programmed to the new WCM BEFORE the new Shaft Lock Module is "married" to the new WCM. 4. Is the vehicle equipped with Steering Shaft Lock Module (ELV)? a. Yes >> Proceed to Step # 5. b. No >>Repair is complete. 5. Program the ELV as follows; a. Select "ECU View". b. Scroll down and select "WCM" in the list of modules. c. Select "Misc. Functions". d. Scroll to "ELV Replaced." e. Press "Start". f. When complete, verify steering shaft lock mechanism is operating. Remove and insert key from the ignition lock cylinder and listen for solenoid "click at lower end of column. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Technical Service Bulletins > Customer Interest for Steering Column Lock: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 6766 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Lock: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition Steering Column Lock: All Technical Service Bulletins Antitheft System - Engine No Crank/No Start Condition NUMBER: 08-007-08 REV. A GROUP: Electrical DATE: July 04,2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-007-08, DATED MARCH 04, 2008. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. DO NOT ORDER PART NUMBER 05026070AP UNTIL JULY 21, 2008. ALL OTHER PART NUMBERS ARE AVAILABLE NOW. SUBJECT: No Engine Crank Or No Engine Start Due To Electronic Lockup Of The WCM / SKREEM OVERVIEW: This bulletin involves the replacement of the Wireless Control Module (WCM), and if equipped, the replacement of the Electric Steering Column Lock (ELV). The WCM is also referred to as the Sentry Key Remote Entry Module (SKREEM). MODELS: 2007 - 2008 (DR/DH/D1/DC/DM) Ram Truck (1500/2500/3500/4500/5500) 2007 - 2008 (JK) Wrangler 2007 - 2008 (J1) Sebring (China) 2007 - 2008 (JS) Avenger/Sebring 2007 - 2008 (KA) Nitro 2008 (KK) Liberty/Cherokee 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber 2006 - 2008 (PT) Chrysler PT Cruiser NOTE: This bulletin applies to vehicles built on or before May 05, 2008 (MDH 0505XX). SYMPTOM/CONDITION: The customer will experience a no engine crank AND a no engine start condition. Also, the remote keyless entry (RKE) system will not operate. This condition may be due to an electrostatic discharge (ESD) from the ignition key into the Wireless Control Module (WCM), causing the WCM to electronically lockup. This condition may occur more frequently in dry and/or cold weather conditions where a sufficient electrostatic charge is more easily produced. This condition is corrected by the replacement of the WCM. DIAGNOSIS: 1. With the condition present (i.e. the vehicle in the no crank / no start condition), connect the StarSCAN(R) scan tool to the vehicle. 2. Turn the ignition switch to the "ON position, and power up the StarSCAN(R). 3. If the WCM is electronically locked up, the StarSCAN(R) will display the WCM as being "off bus". 4. If the no crank / no start condition is present, and the WCM is "off bus", then reset the WCM by temporarily removing the IOD fuse (with the key out of the ignition switch), wait for 10 seconds and then reinstall the IOD fuse. 5. With the IOD fuse reset having been performed, verify that the vehicle will now crank, start, and run. 6. If the condition is temporarily corrected by performing the above steps, and if the part number of the WCM is earlier than the part number of the WCM listed in the part reference table in the Service Bulletin Parts Required Section below, then perform the Repair Procedure. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Lock: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 6772 PARTS REQUIRED: NOTE: The part numbers listed in the following part reference table are to be used as A GUIDE to help determine if the WCM, that is currently in the vehicle, may require replacement. If it is determined that the WCM requires replacement, then ALWAYS REFER TO THE PARTS MANUAL to determine the correct WCM for the specific vehicle in question. In some earlier model years, the WCM may rule (supersede) to one of the part numbers listed in the table. ALWAYS REFER TO THE PARTS MANUAL (not the part reference table) to determine the correct part number ruling (supercedence / substitution). MAKE CERTAIN THAT THE CORRECT WCM IS ORDERED THE FIRST TIME FOR THE SPECIFIC VEHICLE IN QUESTION. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Lock: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 6773 REPAIR PROCEDURE: NOTE: If the vehicle (a JS model vehicle in certain International markets) is equipped with an Electric Steering Column Lock (ELV), then the WCM and the ELV must be replaced. Replace the WCM and then the ELV. Next program the WCM and at least one (1) ignition key BEFORE programming the ELV. IMPORTANT: Not following this repair process correctly will cause the new ELV to fail. NOTE: Insert the ignition key into the ignition lock cylinder. This will move the shaft lock module locking bolt to the unlocked position. LEAVE the key in the lock cylinder while the shaft lock module is being removed. 1. If vehicle is equipped with a Steering Shaft Lock Module (JS - Avenger I Stratus - some International Markets), then the Shaft Lock Module will require replacement. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Security Information > Module, Shaft Lock > Removal and Installation. NOTE: The shaft lock module cannot be removed from the steering column while the locking bolt is in the locked position without irreversibly damaging the column. Before attempting service, the ignition key must have been inserted into the ignition lock cylinder. Then rotate the steering wheel from side to side. If the steering wheel can be rotated, the locking bolt is in the unlocked position. Leave the key in the ignition lock cylinder until shaft lock module removal has been completed. If the steering wheel cannot be rotated, test and repair the wiring circuits between the module and the ignition switch as required. If no problem is found in these circuits, the module has failed with the locking bolt in the locked position and both the module and the steering column must be replaced with new units. 2. Replace the WCM/SKREEM. Refer to TechCONNECT for detailed service information. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Service Information > Module, Sentry Key Remote Entry > Removal and Installation. NOTE: Obtain the vehicle PIN number prior to programming WCM/SKREEM or ELV. NOTE: If during the following steps the PIN number is properly entered but is rejected, then reenter the PIN number again until it is accepted. 3. After both the WCM/SKREEM and the ELV (if equipped) have been replaced, Program the WCM/SKREEM as follows: a. Turn the ignition key to the ON position, (Engine Off) b. Connect the scan tool (StarSCAN(R)) to the data link connector and turn the ignition to the RUN position, (engine off). c. Select "ECU View." d. Scroll down and select "WCM" in the list of modules. e. Select "Misc. Functions." f. Scroll to "WCM Replaced." g. Press "Start". h. Press "Next". i. Select "Show Keyboard". j. Enter the vehicle PIN number. k. Select "Next". l. Verify PIN is correct. m. Select "Next". n. Follow on-screen prompts to complete WCM function programing for Tire Pressure Monitoring (TPM) and so on. 0. Turn the ignition key to the OFF position. Wait 30 seconds. p. Turn the ignition key to the ON position, (Engine Off) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Lock: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 6774 q. Select "ECU View". r. Scroll down and select "WCM" in the list of modules. s. Select "Misc. Functions." t. Select "Program Ign. Keys" and follow on-screen prompts. u. Select "Complete". v. Verify ignition key will start vehicle and the Remote Keyless Entry (RKE) functions operate. CAUTION: If the vehicle is equipped with a Shaft Lock Module (used in some International Markets on JS model vehicles), then at least one (1 ignition key must have been programmed to the new WCM BEFORE the new Shaft Lock Module is "married" to the new WCM. 4. Is the vehicle equipped with Steering Shaft Lock Module (ELV)? a. Yes >> Proceed to Step # 5. b. No >>Repair is complete. 5. Program the ELV as follows; a. Select "ECU View". b. Scroll down and select "WCM" in the list of modules. c. Select "Misc. Functions". d. Scroll to "ELV Replaced." e. Press "Start". f. When complete, verify steering shaft lock mechanism is operating. Remove and insert key from the ignition lock cylinder and listen for solenoid "click at lower end of column. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Lock: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 6775 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Description and Operation Steering Gear: Description and Operation DESCRIPTION The steering gear (2) used is the rack-and-pinion type with power assist. It is mounted on the front suspension crossmember. The outer ends of the outer tie rods attach to the front (steering) knuckles. NOTE: The power steering gear should not be serviced or adjusted. If a malfunction or oil leak occurs with the steering gear, the complete steering gear needs to be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Description and Operation > Page 6779 Steering Gear: Testing and Inspection POWER STEERING GEAR NOTE: This information is designed to be used in conjunction with the diagnostic charts at the beginning of the Steering section. OBJECTIONABLE HISS OR WHISTLE POSSIBLY CAUSED BY A NOISY STEERING GEAR 1. Check and adjust power steering fluid level in the reservoir as necessary. 2. Start the vehicle and heat system by steering lock-to-lock 5 times with the engine running at 3000 rpm. Do not hold the gear against the stops for more than 5 seconds at a time. 3. Return the engine to idle speed. 4. Listen for the noise when turning the wheel slowly off center during a dry park maneuver. 5. Replace power steering gear if the hiss or whistle is present. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal Steering Gear: Service and Repair Removal STEERING GEAR NOTE: Before proceeding, refer to STEERING WARNING. 1. Siphon out as much power steering fluid as possible from the pump. 2. Reposition the floor carpeting to access the intermediate shaft coupling at the base of the column. 3. Position the front wheels of vehicle in the STRAIGHT-AHEAD position, then turn the steering wheel to the right until the intermediate shaft coupling bolt (3) at the base of the column can be accessed. 4. Remove the intermediate shaft coupling bolt (3). Do not separate the intermediate shaft (2) from the steering gear pinion shaft (4) at this time. 5. Return the front wheels of vehicle (and steering wheel) to the STRAIGHT-AHEAD position. Using a steering wheel holder, lock the steering wheel in place to keep it from rotating. This keeps the clockspring in the proper orientation. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal > Page 6782 6. Raise and support the vehicle. 7. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). 8. On each side of the gear, remove the nut (2) from the out tie rod end (4) at the knuckle (3). 9. On each side of the gear, separate the tie rod end (3) from the knuckle (2) using Remover (1), Special Tool 9360. 10. If equipped, remove the engine belly pan. 11. Remove the rear engine mount. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal > Page 6783 12. Remove the front engine mount through-bolt. 13. Remove the three screws (1, 2) securing the heat shield (3) to the crossmember (4). Remove the shield. 14. Remove the return hose (1) at the steering gear (3). 15. Remove the pressure hose (2) at the steering gear (3). 16. Remove the fasteners (1) securing the power steering hose routing clamps (2) to the crossmember. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal > Page 6784 17. Remove the screws (1) securing the stabilizer bushing retainers (3) to the crossmember. 18. Remove the two stabilizer bushing retainers. NOTE: Before removing the front suspension crossmember from the vehicle, the location of the crossmember must be marked on the body of the vehicle. Do this so the crossmember can be relocated, upon reinstallation, against the body of vehicle in the same location as before removal. If the front suspension crossmember is not reinstalled in exactly the same location as before removal, the preset front wheel alignment settings (caster and camber) may be lost. 19. Mark the location of the front crossmember on the body near each mounting bolt using a marker or crayon. Do not use a scratch awl or other tool that can penetrate the protective coating on the body. 20. Support the front crossmember with a transmission jack. 21. Remove the four mounting bolts (6) securing the front crossmember (1) to the body. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal > Page 6785 22. Lower the crossmember enough to access the intermediate shaft coupling (1) at the steering gear pinion shaft (4). Slide the coupling off the pinion shaft. 23. Remove the dash seals (3, 5) as necessary. 24. Remove the two bolts (1) securing the steering gear (2) to the crossmember. 25. Rotate the stabilizer bar up in order to remove the steering gear from the vehicle. 26. Remove the steering gear from the crossmember. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal > Page 6786 Steering Gear: Service and Repair Installation STEERING GEAR 1. Rotate the stabilizer bar up and install the steering gear on the crossmember. 2. Install the two bolts (1) securing the steering gear (2) to the crossmember. Tighten the steering gear mounting bolts to 70 Nm (52 ft. lbs.). 3. Install the dash seals (3, 5) as necessary. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal > Page 6787 4. Center the power steering gear rack in its travel as necessary. NOTE: When installing the front suspension crossmember (1) back in the vehicle, it is very important that the crossmember be attached to the body in exactly the same spot as when it was removed. Otherwise, the vehicle's wheel alignment settings (caster and camber) will be lost. 5. Slowly raise the crossmember (1) into mounted position using the transmission jack matching the crossmember to the marked locations on the body made during removal. 6. Check the positioning of the seals at the dash panel and adjust as necessary. 7. Install the four mounting bolts (6) securing the front crossmember (1) to the body. Tighten the crossmember mounting bolts to 190 Nm (140 ft. lbs.). 8. Remove the transmission jack. 9. Install the retainers (3) over the stabilizer bar cushions. Install all four stabilizer bar cushion retainer screws (1) and tighten them to 30 Nm (22 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal > Page 6788 10. Install the fasteners (1) securing the power steering hose routing clamps (2) to the crossmember. Tighten the screws to 8 Nm (71 in. lbs.). 11. Install the pressure hose (2) at the gear (3). Tighten the tube nut to 32 Nm (24 ft. lbs.). 12. Install the return hose (1) at the gear (3). Tighten the tube nut to 20 Nm (15 ft. lbs.). 13. Position the heat shield (3) and install the three screws (1, 2) securing the shield to the crossmember (4). Tighten the two front mounting screws (1) to 4 Nm (35 in. lbs.). Tighten the rear mounting screw (2) to 17 Nm (150 in. lbs.). 14. Install the front engine mount through-bolt. 15. Install the rear engine mount. 16. If equipped, install the engine belly pan. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal > Page 6789 NOTE: Prior to attaching the outer tie rod end to the knuckle, inspect the tie rod seal boot. If the seal boot is damaged, replace the outer tie rod end. 17. On each side of the gear, install the outer tie rod end (4) into the hole in the knuckle arm (3). Start a NEW tie rod mounting nut (2) onto the stud. While holding the tie rod end stud with a wrench, tighten the nut with a wrench or crowfoot wrench. Tighten the nut to 132 Nm (97 ft. lbs.). 18. On each side of the vehicle, install the tire and wheel assembly (1). Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 19. Lower the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal > Page 6790 20. Remove the steering wheel holder. 21. Verify the front wheels of vehicle are in the STRAIGHT-AHEAD position. 22. Center the intermediate shaft (2) over the steering gear pinion shaft (4), lining up the ends, then slide the intermediate shaft onto the steering gear pinion shaft. 23. From center, rotate the steering wheel to the right approximately 90° or until the intermediate shaft coupling bolt (3) can be easily installed. 24. Install the intermediate shaft coupling bolt (3). Tighten the bolt to 47 Nm (35 ft. lbs.). 25. Reposition the floor carpet (1) in place. 26. Straighten the steering wheel to STRAIGHT-AHEAD position. 27. Fill and bleed the power steering system. 28. Check for fluid leaks. 29. Adjust front wheel toe as necessary. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Description Steering Mounted Controls Communication Module: Description and Operation Description DESCRIPTION This vehicle is equipped with a Steering Column Control Module (SCCM) The SCCM is secured near the top of the steering column below the steering wheel and is completely concealed beneath the steering column shrouds. It is installed as a modular unit that supports the left (lighting) multi-function switch (1) and right (wiper) multi-function switch (6). The controls for each of these switches extend through appropriate clearance holes provided in the steering column shrouds. The microprocessor-based Steering Control Module (SCM) (2) utilizes integrated circuitry and information carried on the Controller Area Network (CAN) data bus along with several hard wired analog and multiplexed inputs to monitor both the right and left multi-function switches. The SCCM uses a Local Interconnect Network (LIN) data bus for exterior lighting and wiper functions. The LIN data is sent to the Cab Compartment Node (CCN) and the CCN then sends it out on the CAN data bus. The SCCM is available for service replacement as a unit or each individual component: - Clockspring (with integral Steering Angle Sensor if equipped) - Left Multi-Function Switch - Right Multi-Function Switch Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Description > Page 6795 Steering Mounted Controls Communication Module: Description and Operation Operation OPERATION The Steering Control Module (SCM) communicates over the Local Interconnect Network (LIN) data bus with other electronic modules in the vehicle and/or a diagnostic scan tool. The horn switch circuits pass through the clockspring to the Cab Compartment Node (CCN) and the CCN sends a CAN message to the Totally Integrated Power Module (TIPM) to control the horn. The CCN stores Diagnostic Trouble Codes (DTC's) for the SCM. The right (wiper) multi-function switch has several inputs to the CCN. The SCM is connected to a fused B(+) circuit and receives a path to ground at all times. These connections allow it to remain functional regardless of the ignition switch position. The driver airbag squib circuits of the clockspring, the horn, and the speed control switch circuits pass through the SCM, but the SCM does not monitor, and has no control outputs related to these circuits. Any other input to the SCM that would cause a vehicle system to function but does not require that the ignition switch be in the On position, such as turning on the lights or sounding the horn, prompts the SCM to wake up and transmit on the CAN data bus. The most reliable, efficient, and accurate means to diagnose the SCM, the CAN data bus, the hard wired inputs or the electronic communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. The integral SCM is not available for separate service replacement. If found inoperative or defective, the entire left (lighting) multi-function switch must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Removal Steering Wheel: Service and Repair Removal REMOVAL WARNING: - Do not place a non-deployed airbag face down on a hard surface. The airbag will propel into the air if accidentally deployed, and could result in serious or fatal injury. - Disconnect and isolate the battery negative (ground) cable before beginning steering wheel removal or installation. This will disable the airbag system. Failure to disconnect the battery could result in accidental airbag deployment and possible personal injury. - Allow the airbag system capacitor to discharge for two minutes before removing the steering wheel or any airbag system component. 1. Adjust the steering wheel so that the tires are in the STRAIGHT-AHEAD position. 2. Disconnect and isolate the battery negative cable. 3. Remove the driver airbag (3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Removal > Page 6800 4. Disconnect the wiring connector (2) at the clockspring. 5. While holding the steering wheel firmly in place, remove the retaining bolt (2) securing the steering wheel to the steering column shaft. CAUTION: When installing a wheel puller on the steering wheel, be sure the puller jaws are fully seated around the steering wheel base (1). If the jaws are not fully seated, the jaws may slip off the steering wheel while attempting to remove the steering wheel. Also, threading the retaining bolt (2) back in the end of the shaft until approximately 13 mm (0.5 in.) of thread is showing between the wheel and the head of the bolt allows a safe reaction surface for the puller to work against. 6. Thread the wheel retaining bolt (2) back into the end of the shaft until approximately 13 mm (0.5 in.) of thread is showing between the wheel and the head of the bolt. 7. Remove the screw (3) for the speed control switch in order to install the steering wheel puller tool. 8. Install a steering wheel puller on the steering wheel. CAUTION: Do not bump or hammer on steering wheel or steering column shaft when removing steering wheel from steering column. 9. While holding the steering wheel firmly in the STRAIGHT-AHEAD position, remove steering wheel from the steering column shaft using the Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Removal > Page 6801 puller. 10. Remove the wheel retaining bolt (2) and the steering wheel. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Removal > Page 6802 Steering Wheel: Service and Repair Installation INSTALLATION 1. Confirm that: a. The front wheels are in the STRAIGHT-AHEAD position. b. The turn signal stalk is in the NEUTRAL position. CAUTION: Do not install the steering wheel onto the shaft of the steering column by driving it onto the shaft. 2. Align the steering wheel's wide mounting spline with the steering column shaft missing spline area and push the wheel onto the shaft. Make sure the clockspring lines up with the back of the wheel and does not bind. 3. Install the steering wheel retaining bolt (2) and tighten it until the steering wheel is fully installed on shaft. Tighten the steering wheel retaining bolt to 43 Nm (32 ft. lbs.). 4. Install the speed control screw (3) that was removed for the puller. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Removal > Page 6803 5. Connect the wiring connector (2) at the clockspring. 6. Install the driver airbag (3). WARNING: Do not connect battery negative cable yet. Refer first to Airbag System Test. 7. Reconnect the battery using the Airbag System Test procedure in Restraints. 8. Verify vehicle and system operation. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Testing and Inspection Tie Rod End: Testing and Inspection TIE ROD Tie rod free-play can be measured using the following hand methods: NOTE: When checking free-play, DO NOT rotate the tie rod. Just because a tie rod rotates easily does not mean that it is necessarily faulty. NOTE: Always check and repair (if necessary) outer tie rod free-play before checking inner tie rod free-play. False results can otherwise be obtained. OUTER TIE ROD Grasp the outer tie rod near the ball stud and attempt to move the tie rod straight up and down. If any free-play is felt, replace the outer tie rod. If no free-play is felt at the outer tie rod, attempt to move the inner tie rod in the same manner. Refer to the following procedure. INNER TIE ROD Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Testing and Inspection > Page 6808 Grasp the inner tie rod near the steering gear bellows and attempt to move the tie rod straight up and down. If any free-play is felt, replace the steering gear. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Removal - Outer Tie Rod End Tie Rod End: Service and Repair Removal - Outer Tie Rod End OUTER TIE ROD END 1. Raise and support the vehicle. 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). 3. Loosen the tie rod jam nut (5). 4. Remove the nut (2) attaching the outer tie rod (4) to the knuckle (3). To do this, hold the tie rod end stud with a wrench while loosening and removing the nut with a standard wrench or crowfoot wrench. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Removal - Outer Tie Rod End > Page 6811 5. Release the tie rod end (3) from the knuckle (2) using Remover, Special Tool 9360 (1) 6. Remove the outer tie rod (3) from the knuckle (2). NOTE: When unscrewing the outer tie rod from inner, count the number of revolutions to take it off. This action will aid in installation, getting the toe close to where it needs to be when setting the wheel alignment. 7. Remove the outer tie rod from the inner tie rod. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Removal - Outer Tie Rod End > Page 6812 Tie Rod End: Service and Repair Installation - Outer Tie Rod End OUTER TIE ROD END 1. If it is not already installed, install the jam nut (5) on the inner tie rod threads. 2. Thread the outer tie rod (4) onto the inner tie rod approximately the same amount of revolutions as the original was installed. 3. Thread the jam nut (5) down the inner tie rod far enough to hold the outer tie rod. Do not tighten the jam nut at this time. 4. Install the outer tie rod ball stud into the hole in the knuckle arm (3). Start a NEW tie rod mounting nut (2) onto the stud. While holding the tie rod end stud with a wrench, tighten the nut with a wrench or crowfoot wrench. Tighten the nut to 132 Nm (97 ft. lbs.). 5. Install the tire and wheel assembly (1). Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 6. Lower the vehicle. 7. Adjust the front wheel toe setting. 8. Tighten the tie rod jam nut to 75 Nm (55 ft. lbs.) once wheel toe is set. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Removal Ball Joint: Service and Repair Removal REMOVAL CAUTION: This procedure is designed to be used only if a seal boot is damaged during related service procedures. It is not to be used as a repair procedure for a cut seal boot on a vehicle that has been driven and exposed to road and weather conditions. 1. Remove the lower control arm from the vehicle. 2. Using a screwdriver or other suitable tool (2), pry the seal boot (1) off of the ball joint. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Removal > Page 6818 Ball Joint: Service and Repair Installation INSTALLATION CAUTION: This procedure is designed to be used only if a seal boot is damaged during related service procedures. It is not to be used as a repair procedure for a cut seal boot on a vehicle that has been driven and exposed to road and weather conditions. 1. Place a liberal dab of Mopar(R) Multi-Mileage Lube (No more than 10g) or equivalent around the base of the ball joint stud at the socket. 2. Position the ball joint stud straight up. 3. Place the NEW ball joint seal boot over the ball joint stud. 4. By hand, start the seal boot over the sides of the ball joint. CAUTION: Prior to installing the sealing boot using Remover/Installer, Special Tool 6289-4, make sure there are no burrs on the inside of the tool. Remove any burrs and lubricate with a small amount of Mopar(R) Multi-Mileage Lube or equivalent. 5. Place Remover/Installer, Special Tool 6289-4, onto the screw-drive of Ball Joint Press, Special Tool C-4212F. 6. Place Remover/Installer, Special Tool 6289-6, angle-cut end up into the cup of Ball Joint Press, Special Tool C-4212F. Before tightening the set, turn the Remover/Installer so that the tallest point of the angle-cut is away from the body of the control arm when installing the seal boot. 7. Place the control arm ball joint into Remover/Installer 6289-6. Rotate the arm left or right until the tallest point of the angle cut on the Remover/Installer is away from the body of the control arm. 8. Lower Remover/Installer 6289-4 onto outer lip of ball joint seal. 9. By hand, tighten the Ball Joint Press screw-drive installing the seal boot. Tighten the screw-drive until the seal boot is seated squarely down against the top surface of the lower control arm (3). It may be necessary to use a wrench to seat the seal boot, but do not overtighten. 10. Remove the tools and wipe any grease off the ball joint stud using a clean shop towel with Mopar(R) Brake Parts Cleaner applied to it. 11. Install the lower control arm. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Testing and Inspection Control Arm: Testing and Inspection LOWER CONTROL ARM Inspect the lower control arm for signs of damage from contact with the ground or road debris. If the lower control arm shows any sign of damage, look for distortion. Do not attempt to repair or straighten a broken or bent lower control arm. If damaged, the lower control arm stamping is serviced only as a complete component. Inspect both lower control arm isolator bushings for severe deterioration and replace the lower control arm as required. Inspect the ball joint per the inspection procedure and replace the lower control arm required. The only serviceable component of the lower control arm is the ball joint seal boot. It should only be replaced if damaged during service of a chassis component. Otherwise, replace the entire control arm. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension Control Arm: Service and Repair Front Suspension Lower Control Arm - Removal REMOVAL NOTE: Before proceeding, refer to FRONT SUSPENSION WARNING. 1. Raise and support the vehicle. 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). 3. Remove the nut (5) and pinch bolt (4) clamping the ball joint (6) stud to the knuckle (3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 6824 CAUTION: Upon removing the knuckle from the ball joint stud, do not pull outward on the knuckle. Pulling the knuckle outward at this point can separate the inner C/V joint on the halfshaft thus damaging it. CAUTION: Use care when separating the ball joint stud (4) from the knuckle (1), so the ball joint seal does not get cut. 4. Using an appropriate prying tool (2), separate the ball joint stud (4) from the knuckle (1) by prying down on lower control arm (3) and up against the ball joint boss on the knuckle. 5. Remove the front bolt (2) attaching the lower control arm (3) to the front suspension crossmember (4). 6. Remove the nut (1) on the rear bolt attaching the lower control arm (3) to the front suspension crossmember (4). Remove the bolt. 7. Remove the lower control arm (3) from the crossmember (4). Lower Control Arm - Installation INSTALLATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 6825 1. Place the lower control arm (2) into the front suspension crossmember (1). 2. Insert the rear bolt (3) up through the crossmember (1) and lower control arm (2). 3. Install, but do not fully tighten, the nut (1) on the rear bolt attaching the lower control arm (3) to the crossmember (4). 4. Install, but do not fully tighten, the front bolt (2) attaching the lower control arm to the crossmember. 5. With no weight or obstruction on the lower control arm, tighten the lower control arm rear mounting bolt nut (1) to 183 Nm (135 ft. lbs.). 6. With no weight or obstruction on the lower control arm, tighten the lower control arm front pivot bolt (2) to 183 Nm (135 ft. lbs.). 7. Install the ball joint (6) stud into the knuckle (3), aligning the bolt hole in the knuckle boss with the groove formed in the side of the ball joint stud. 8. Install a NEW ball joint stud pinch bolt (4) and nut (5). Tighten the nut to 82 Nm (60 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 6826 9. Install tire and wheel assembly (1). Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 10. Lower the vehicle. 11. Perform wheel alignment as necessary. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 6827 Control Arm: Service and Repair Rear Suspension Lower Control Arm - Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). 3. If equipped, while holding the stabilizer bar link lower stud stationary, remove the nut (2) securing the link to the lower control arm (4). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 6828 4. Remove the lower shock mounting nut (3) and bolt (1). 5. Remove the stay brace (3) mounting screws (2). Remove the stay brace. 6. Remove the nut (2) and bolt (3) securing the lower control arm (4) to the trailing link (1). 7. Remove the nut (6) and bolt (5) securing the lower control arm (4) to the crossmember (7). 8. Remove the lower control arm (4). Lower Control Arm - Installation INSTALLATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 6829 1. Position the lower control arm and install the bolt (5) and nut (6) securing the lower control arm (4) to the crossmember (7). Do not tighten at this time. 2. Install the bolt (3) and nut (2) securing the lower control arm (4) to the trailing link (1). Do not tighten at this time. 3. Install the stay brace (3) on the crossmember (1). Install and tighten the mounting screws (2) to 25 Nm (18 ft. lbs.). 4. Install the mounting bolt (1) and nut (3) fastening the shock assembly (2) to the lower control arm (4). Do not tighten at this time. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 6830 NOTE: When attaching a stabilizer bar link to the lower control arm it is important that the lower mounting stud be positioned properly. The lower mounting stud on the right side link needs to point toward the rear of the vehicle when inserted through the lower control arm mounting flange. The left side link lower stud needs to point toward the front of the vehicle. Otherwise the suspension geometry will not function properly. 5. If equipped, attach the stabilizer bar link to the lower control arm (4). Install the nut (2) and while holding the stabilizer bar link lower stud stationary, tighten the nut (2) to 58 Nm (43 ft. lbs.). 6. Install tire and wheel assembly (1). Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 7. Lower the vehicle. 8. Position the vehicle on an alignment rack/drive-on lift. Raise the vehicle as necessary to access mounting bolts and nuts. 9. Tighten the lower control arm mounting bolt nut at the crossmember to 95 Nm (70 ft. lbs.). 10. Tighten the lower control arm mounting bolt nut at the trailing link to 95 Nm (70 ft. lbs.). 11. Tighten the shock assembly lower mounting bolt nut to 99 Nm (73 ft. lbs.). 12. Perform wheel alignment as necessary. Upper Control Arm - Removal REMOVAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 6831 1. Raise and support the vehicle. 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). 3. Remove the nut (4) and bolt (3) securing the upper control arm (1) to the trailing link. 4. Remove the bolt (2) securing the upper control arm (1) to the crossmember. 5. Remove the upper control arm (1). Upper Control Arm - Installation INSTALLATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 6832 1. Position the upper control arm (1) and install the bolt (2) securing the arm to the crossmember. Do not tighten at this time. 2. Install the bolt (3) and nut (4) securing the upper control arm (1) to the trailing link. Do not tighten at this time. 3. Install tire and wheel assembly (1). Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 4. Lower the vehicle. 5. Position the vehicle on an alignment rack/drive-on lift. Raise the vehicle as necessary to access mounting bolts and nuts. 6. Tighten the upper control arm mounting bolt at the crossmember to 95 Nm (70 ft. lbs.). 7. Tighten the upper control arm mounting bolt nut at the trailing link to 95 Nm (70 ft. lbs.). 8. Perform wheel alignment as necessary. Toe Link - Removal REMOVAL 1. Raise and support the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 6833 2. Remove the bolt (2) securing the toe link (3) to the trailing link. 3. Mark the position of the cam bolt cam on the crossmember using a paint marker or crayon. This mark will be used upon installation to help get the alignment close prior to performing rear wheel alignment. Do not use any type marker that will scratch or damage the surface of the crossmember. 4. While holding the cam bolt head (3) stationary, loosen and remove the toe link mounting cam bolt nut (1) and washer. Remove the cam bolt. 5. Remove the toe link (2). Toe Link - Installation INSTALLATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 6834 CAUTION: When installing the cam bolt (3) and washer make sure the cams stay inside the abutments built into the crossmember. Failure to do so can damage the abutments and make toe adjustment difficult. 1. Position the toe link (2) and install the cam bolt (3) from the front through the crossmember and link. Match the cam on the bolt to the marks made during removal or position the top of the cam to the 12 O'clock position. 2. Install the cam washer and nut (1) securing the toe link (2) to the crossmember. Do not tighten at this time. 3. Install the bolt (2) securing the link to the trailing link. To install the bolt it may be necessary to flex the trailing link body mount bushing inward or outward using an appropriate prying tool. Do not tighten at this time. 4. Lower the vehicle. 5. Position the vehicle on an alignment rack/drive-on lift. Raise the vehicle as necessary to access mounting bolts and nuts. 6. Tighten the toe link mounting bolt at the trailing link to 95 Nm (70 ft. lbs.). 7. Perform wheel alignment as necessary. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 6835 8. Once rear toe is set, while holding the cam bolt head (3) stationary, tighten the toe link mounting cam bolt nut (1) to 35 Nm (26 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Service and Repair > Front Crossmember Fore/Aft Front Cross-Member: Service and Repair Front Crossmember Fore/Aft Removal REMOVAL 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the four wheel well screws. 3. If equipped, remove the three front screws (4), the three rear screws (2) and one push pin fastener from the center of the belly pan. 4. Remove the crossmember bolts (1, 2 and 3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Service and Repair > Front Crossmember Fore/Aft > Page 6841 5. Remove the engine roll mount (3) through bolt (2) and remove the fore/aft crossmember (4). Installation INSTALLATION 1. Install the fore/aft crossmember and install the engine anti-roll mount (3) through bolt (2). 2. Install the bolts (1, 2 and 3), and tighten using the following sequence: a. Tighten the bolt (1) to 78 Nm (58 ft. lbs.). b. Tighten the bolt (2) to 78 Nm (58 ft. lbs.). c. Tighten the bolt (3) to 129 Nm (95 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Service and Repair > Front Crossmember Fore/Aft > Page 6842 3. Tighten the bolt (2) to 65 Nm (48 ft. lbs.). 4. If equipped, install the belly pan. 5. Install the three front screws (4), the three rear screws (2) and on push pin fastener into the center of the belly pan. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Service and Repair > Front Crossmember Fore/Aft > Page 6843 Front Cross-Member: Service and Repair Front Suspension Crossmember Removal REMOVAL 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the four wheel well screws. 3. If equipped, remove the three front screws (4), the three rear screws (2) and one push pin fastener from the center of the belly pan. 4. Remove the rear roll mount (4) through bolt (2). 5. Remove the three bolts (3) attaching the rear roll mount (5) to the crossmember and remove the mount. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Service and Repair > Front Crossmember Fore/Aft > Page 6844 6. Remove the for/aft crossmember (4). 7. Remove the front wheels (1). 8. Remove the lower ball joint (6) pinch bolts (4) and nuts (5). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Service and Repair > Front Crossmember Fore/Aft > Page 6845 9. Remove the bolt attaching the pressure line routing bracket to the steering gear. 10. Remove the bolt attaching the return line to the crossmember. 11. Remove the sway bar bushing bolts (1) and support the sway bar (2) up in the vehicle. 12. Remove the steering gear mounting bolts (1) and support the steering gear (2) up in the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Service and Repair > Front Crossmember Fore/Aft > Page 6846 13. Mark the crossmember (3) to body location (1) using a grease pencil (2) or equivalent. 14. Support the crossmember with a suitable lifting device. 15. Remove the crossmember bolts (1 and 2) and lower the crossmember from the vehicle. 16. Remove the lower control arm (3) front pivot bolts (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Service and Repair > Front Crossmember Fore/Aft > Page 6847 17. Remove the lower control arm rear pivot bolts (3) and separate the lower control arms from the crossmember (1). Installation INSTALLATION 1. Install the lower control arms and install the rear pivot bolts (3). 2. Install the front pivot bolts (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Service and Repair > Front Crossmember Fore/Aft > Page 6848 3. Support the crossmember on a suitable lifting device. 4. Raise the crossmember into position onto the vehicle. 5. Install the bolts (1 and 2) and align the engine cradle to the marks made during removal. 6. Tighten the bolts to 190 Nm (140 ft. lbs.). 7. Position the steering gear back into place and install the bolts (1). 8. Tighten the bolts to 61 Nm (45 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Service and Repair > Front Crossmember Fore/Aft > Page 6849 9. Position the stabilizer bar (2) back into place and install the bushing bolts (1). 10. Tighten the bolts to 61 Nm (45 ft. lbs.). 11. Position the power steering lines back into place and install the support bracket (2) bolts (1). 12. Tighten the bolts to 8 Nm (70 ft. lbs.). 13. Connect the lower ball joint stud (6) to the knuckle (3). 14. Install a NEW ball joint stud pinch bolt (4) and nut (5). Tighten the nut to 82 Nm (60 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Service and Repair > Front Crossmember Fore/Aft > Page 6850 15. Install the fore/aft crossmember (4). 16. Install the front wheels (1). 17. With the full weight of the vehicle on the suspension tighten the front control arm bushing bolts to 123 Nm (91 ft. lbs.) 18. Perform wheel alignment as necessary. 19. Install the rear roll mount (4) and install the three bolts (3) attaching it to the crossmember. 20. Tighten the bolts (3) to 153 Nm (112 ft. lbs.). 21. Install the through bolt (2) and tighten to 65 Nm (48 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Service and Repair > Front Crossmember Fore/Aft > Page 6851 22. If equipped, install the belly pan. 23. Install the three front screws (4), the three rear screws (2) and push pin fasteners into the center of the belly pan. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Removal Rear Cross-Member: Service and Repair Removal REMOVAL 1. Remove the park brake shoes. 2. Park brake cable from lever. 3. Remove the hair pin clip and separate the brake cable (2) from the backing plate (3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Removal > Page 6856 4. Remove the bolt (2) and separate the brake line (1) from the trailing arm (3). 5. Remove the bolt (1), the clip (2) and separate the brake line (3) from the trailing arm. 6. Separate the wheel speed sensors and position aside as necessary to remove the crossmember. 7. If equipped, remove the rear drive module. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Removal > Page 6857 8. Remove the cotter pins (2), the nuts (3) and the washers (4). 9. Remove both half shafts. 10. Remove the lower strut bolts. 11. Remove the trailing link bushing bolts. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Removal > Page 6858 12. Support the rear cradle with a suitable lifting device. 13. Remove the rear cradle bolts and lower the cradle assembly from vehicle. 14. Remove the lower stabilizer link nuts (2). 15. Remove the lower link bolts (5 and 6) at the cradle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Removal > Page 6859 16. Remove the upper link bolts (2) at the cradle. 17. Remove the toe link cam bolts (1) at the cradle. 18. Remove the suspension knuckle assemblies. 19. Remove the stabilizer bushing bolts (1) and separate the stabilizer bar from the cradle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Removal > Page 6860 Rear Cross-Member: Service and Repair Installation INSTALLATION 1. Install the stabilizer bar and install the bushings and bolts (1). 2. Tighten the bolts to 61 Nm (45 ft. lbs.). 3. Position the suspension knuckle assemblies back into position onto the crossmember. 4. Install the toe link cam bolts (1) at the cradle. 5. Tighten the bolts to 35 Nm (26 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Removal > Page 6861 6. Install the upper link bolts (2) at the cradle. 7. Tighten the bolts to 90 Nm (70 ft. lbs.). 8. Install the lower link bolts (5 and 6) at the cradle. 9. Tighten the bolts to 90 Nm (70 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Removal > Page 6862 10. Install the stabilizer link nuts (2). 11. Tighten the nuts to 58 Nm (43 ft. lbs.). 12. Support the rear cradle assembly (1) with a suitable lifting device and position back into the vehicle. 13. Install the cradle bolts (2 and 3): a. Tighten the front bolts (2) first to 110 Nm (81 ft. lbs.). b. Tighten the rear bolts (3) next to 110 Nm (81 ft. lbs.). 14. Install the trailing link (1) bushing bolts (2 and 3): a. Tighten the inboard bolts (3) first to 110 Nm (81 ft. lbs.). b. Tighten the outboard bolts (2) next to 110 Nm (81 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Removal > Page 6863 15. Install the lower strut bolts (1). 16. Tighten the bolts to 99 Nm 73 ft. lbs.). 17. If equipped, install the rear half shafts. 18. Install the nuts (3) and washers (4). 19. Tighten the nuts to 244 Nm (180 ft. lbs.). 20. Install new cotter pins (2). 21. Install the rear drive module (1). 22. Install the wheel speed sensor back. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Removal > Page 6864 23. Position the brake lines (3) back into place, connect the clips (2) and install the bolts (1). 24. Tighten the bolts to 15 Nm (11 ft. lbs.). 25. Position the brake lines (1) back into place, and install the bolts (2). 26. Tighten the bolts to 23 Nm (17 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Removal > Page 6865 27. Install the brake cable (2) onto the backing plate (3) and install the hair pin clip (1). 28. Connect the brake cable to the park brake lever. 29. Install the park brake shoes. 30. Check and adjust wheel alignment as necessary. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Description and Operation Front Steering Knuckle: Description and Operation DESCRIPTION The knuckle (1) is a single casting with legs machined for attachment to the front strut assembly on the top, lower control arm ball joint on the bottom, and steering linkage on the trailing end. The knuckle also has two machined, drilled and tapped legs on the leading end casting to support and align the front disc brake caliper adapter. The knuckle supports the wheel bearing (5) and hub (3). The hub is pressed into a sealed-for-life wheel bearing that is pressed into the knuckle. A snap ring also holds the bearing in place. A shield is pressed onto the knuckle behind the hub. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Description and Operation > Page 6869 Front Steering Knuckle: Testing and Inspection KNUCKLE The front suspension knuckle is not a repairable component of the front suspension. It must be replaced if found to be damaged in any way. If it is determined that the knuckle is bent when servicing the vehicle, no attempt is to be made to straighten the knuckle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal Front Steering Knuckle: Service and Repair Removal REMOVAL NOTE: Before proceeding, review all Warnings and Cautions. 1. Raise and support the vehicle. 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). 3. Remove the cotter pin (2) from the hub nut (3). 4. While a helper applies the brakes to keep the hub (1) from rotating, remove the hub nut (3) and washer (4) from the axle half shaft. 5. Access and remove the front brake rotor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 6872 6. Remove the routing clip (1) securing wheel speed sensor cable to the knuckle (4). 7. Remove the screw (2) fastening the wheel speed sensor head (3) to the knuckle (4). Pull the sensor head out of the knuckle. 8. Remove the nut (2) attaching the outer tie rod (7) to the knuckle (3). To do this, hold the tie rod end stud with a wrench while loosening and removing the nut with a standard wrench or crowfoot wrench. 9. Release the outer tie rod end (3) from the knuckle (2) using Remover (1), Special Tool 9360. 10. Remove the outer tie rod from the knuckle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 6873 11. Remove the nut (5) and pinch bolt (4) clamping the ball joint stud (6) to the knuckle (3). CAUTION: The strut assembly-to-knuckle attaching bolts (5) are serrated and must not be turned during removal. Proper removal is required. Refer to the following steps for the correct method. 12. While holding the bolt heads stationary, remove the two nuts (2) from the bolts (5) attaching the strut (3) to the knuckle (6). 13. Remove the two bolts (5) attaching the strut (3) to the knuckle (6) using a pin punch. CAUTION: Use care when separating the ball joint stud (4) from the knuckle (1), so the ball joint seal does not get cut. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 6874 14. Using an appropriate prying tool (2), separate the ball joint stud (4) from the knuckle (1) by prying down on lower control arm (3) and up against the ball joint boss on the knuckle. NOTE: Do not allow the half shaft (1) to hang by the inner C/V joint; it must be supported to keep the joint from separating during this operation. 15. Pull the knuckle (3) off the half shaft (1) outer C/V joint splines and remove the knuckle from the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 6875 Front Steering Knuckle: Service and Repair Installation INSTALLATION 1. Slide the hub of the knuckle (3) onto the splines of the halfshaft outer C/V joint (1). 2. Install the knuckle (3) onto the ball joint (6) stud aligning the bolt hole in the knuckle boss with the groove formed into the side of the ball joint stud. 3. Install a NEW ball joint stud pinch bolt (4) and nut (5). Tighten the nut to 82 Nm (60 ft. lbs.). CAUTION: The strut assembly-to-knuckle attaching bolts (2) are serrated and must not be turned during installation. Install the nuts while holding the bolts stationary in the steering knuckle. Refer to the following step. 4. Position the lower end of the strut assembly (3) in line with the upper end of the knuckle (6), aligning the mounting holes. Install the two mounting bolts (5). 5. Install the nuts (2) on the two bolts (5). While holding the bolts in place, tighten the nuts to 84 Nm (62 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 6876 6. Install the outer tie rod (7) ball stud into the hole in the knuckle (3) arm. Start the tie rod end-to-knuckle nut (2) onto the stud. While holding the tie rod end stud with a wrench, tighten the nut with a wrench or crowfoot wrench to 132 Nm (97 ft. lbs.). 7. Install the wheel speed sensor head (3) into the knuckle (4). Install the mounting screw (2) and tighten it to 12 Nm (106 in. lbs.). 8. Install the routing clip (1) securing the wheel speed sensor cable to the knuckle (4). 9. Install the brake rotor, disc brake caliper and adapter. 10. Clean all foreign matter from the threads of the halfshaft outer C/V joint. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 6877 11. Install the washer (4) and hub nut (3) on the end of the halfshaft and snug it. 12. While a helper applies the brakes to keep the hub (1) from rotating, tighten the hub nut (3) to 245 Nm (181 ft. lbs.). 13. Insert the cotter pin (2) through the notches in the nut and the hole in halfshaft. If the notches in the nut do not line up with the hole in the halfshaft, continue to tighten the nut until they do. Do not loosen the nut. 14. Wrap the cotter pin (2) ends tightly around the lock nut. 15. Install tire and wheel assembly (1). Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 16. Lower the vehicle. NOTE: If the original knuckle is being reinstalled, wheel alignment may not be necessary due to Net-Build design. 17. Perform wheel alignment as necessary. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle Alignment Link > Component Information > Service and Repair > Removal Rear Knuckle Alignment Link: Service and Repair Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the bolt (2) securing the toe link (3) to the trailing link. 3. Mark the position of the cam bolt cam on the crossmember using a paint marker or crayon. This mark will be used upon installation to help get the alignment close prior to performing rear wheel alignment. Do not use any type marker that will scratch or damage the surface of the crossmember. 4. While holding the cam bolt head (3) stationary, loosen and remove the toe link mounting cam bolt nut (1) and washer. Remove the cam bolt. 5. Remove the toe link (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle Alignment Link > Component Information > Service and Repair > Removal > Page 6882 Rear Knuckle Alignment Link: Service and Repair Installation INSTALLATION CAUTION: When installing the cam bolt (3) and washer make sure the cams stay inside the abutments built into the crossmember. Failure to do so can damage the abutments and make toe adjustment difficult. 1. Position the toe link (2) and install the cam bolt (3) from the front through the crossmember and link. Match the cam on the bolt to the marks made during removal or position the top of the cam to the 12 O'clock position. 2. Install the cam washer and nut (1) securing the toe link (2) to the crossmember. Do not tighten at this time. 3. Install the bolt (2) securing the link to the trailing link. To install the bolt it may be necessary to flex the trailing link body mount bushing inward or outward using an appropriate prying tool. Do not tighten at this time. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle Alignment Link > Component Information > Service and Repair > Removal > Page 6883 4. Lower the vehicle. 5. Position the vehicle on an alignment rack/drive-on lift. Raise the vehicle as necessary to access mounting bolts and nuts. 6. Tighten the toe link mounting bolt at the trailing link to 95 Nm (70 ft. lbs.). 7. Perform wheel alignment as necessary. 8. Once rear toe is set, while holding the cam bolt head (3) stationary, tighten the toe link mounting cam bolt nut (1) to 35 Nm (26 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Technical Service Bulletins > Steering - ESP Lamp On Possible DTC C121A/C2205 Steering Angle Sensor: Technical Service Bulletins Steering - ESP Lamp On Possible DTC C121A/C2205 NUMBER: 08-010-07 GROUP: Vehicle Performance DATE: May 17, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: DTC's C121A / C2205 - Steering Angle Sensor - Not Initialized / Internal OVERVIEW: This bulletin involves selectively erasing and reprogramming the Steering Angle Sensor (SAS) with new software. MODELS: 2007 (JK) Wrangler 2007 (JS) Sebring 2007 (KA) Nitro 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to vehicles built on or before April 12, 2007 (MDH 0412XX). SYMPTOM/CONDITION: The vehicle operator may experience an illumination of the Electronic Stability Program (ESP) lamp on the vehicle instrument cluster. The ESP lamp illumination may be due to the following Diagnostic Trouble Codes (DTC's): C121A - Steering Angle Sensor Not Initialized C2205 - Steering Angle Sensor Internal This condition, and DTC's, may be intermittent. If the above DTC's occur during a drive cycle, then the ESP lamp will remain illuminated until the end of that drive cycle (key off). DIAGNOSIS: Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Technical Service Bulletins > Steering - ESP Lamp On Possible DTC C121A/C2205 > Page 6889 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 7.04 SPI or higher. The software release level is visible in the blue header at the top of the StarSCAN® screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. For instruction on setting up your StarSCAN® for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU (SAS) part number. Using the StarSCAN(R) at the "Home screen: a. Select "ECU View" b. Touch the screen to highlight the ECU (SAS) in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Technical Service Bulletins > Steering - ESP Lamp On Possible DTC C121A/C2205 > Page 6890 k. When the update is complete, select "OK". NOTE: Due to the ECU (SAS) programming procedure, a DTC may be set in other electronic modules within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front Suspension Stabilizer Bar: Service and Repair Front Suspension Removal REMOVAL NOTE: Before proceeding, refer to FRONT SUSPENSION WARNING. 1. Raise and support the vehicle. 2. If equipped, remove the engine belly pan. 3. Remove the rear engine mount. 4. Remove the front engine mount through-bolt. 5. Remove the fasteners (1) securing the power steering hose routing clamps (2) to the crossmember. 6. At each end of the stabilizer bar, while holding the stabilizer bar link (1) lower stud stationary, remove the nut (3) securing the link to the stabilizer bar (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front Suspension > Page 6895 7. Remove the screws (1) securing the stabilizer bushing retainers (3) to the crossmember. 8. Remove the two stabilizer bushing retainers. 9. Utilizing the slit cut into the cushions (bushings), remove the two cushions from the stabilizer bar. NOTE: Before removing the front suspension crossmember from the vehicle, the location of the crossmember must be marked on the body of the vehicle. Do this so the crossmember can be relocated, upon reinstallation, against the body of vehicle in the same location as before removal. If the front suspension crossmember is not reinstalled in exactly the same location as before removal, the preset front wheel alignment settings (caster and camber) may be lost. 10. Mark the location of the front crossmember on the body near each mounting bolt. 11. Support the crossmember with a transmission jack. 12. Remove the four mounting bolts (6) securing the front crossmember (1) to the body. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front Suspension > Page 6896 13. Remove the two bolts (1) securing the steering gear (2) to the crossmember. 14. Support the steering gear using a bungee cord or other to keep the steering gear from lowering when the crossmember is lowered. 15. Slowly lower the crossmember until there is enough space present to remove the stabilizer bar between the rear of the crossmember and the body. Due to the fact that the fore-and-aft crossmember is still attached, do not lower crossmember any more than necessary to remove the stabilizer bar. 16. Remove the stabilizer bar out over rear of crossmember. Installation INSTALLATION NOTE: Before stabilizer bar installation, inspect the cushions and links for excessive wear, cracks, damage and distortion. Replace any pieces failing inspection. NOTE: Before installing the stabilizer bar, make sure the bar is not upsidedown. The stabilizer bar (1) must be installed so that when in mounted position, the ends of the bar curve over the top of the steering gear before attaching to the links. 1. Install the stabilizer bar, link ends first, from the rear over top of the crossmember. Curve the ends of the bar over the steering gear. 2. Slowly raise the crossmember (1) into mounted position using the transmission jack matching the crossmember to the marked locations on the body made during removal. 3. Install the four mounting bolts (6) securing the front crossmember (1) to the body. Tighten the crossmember mounting bolts to 190 Nm (140 ft. lbs.). 4. Remove the transmission jack. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front Suspension > Page 6897 5. Remove the bungee cord or other supporting the steering gear (2). 6. Install the two bolts (1) securing the steering gear (2) to the crossmember. Tighten the steering gear mounting bolts to 70 Nm (52 ft. lbs.). 7. Install the two cushions (bushings) on the stabilizer bar utilizing the slit cut into the cushion sides. 8. Install the two stabilizer bushing retainers (3) over the cushions. 9. Install the screws (1) securing the stabilizer bushing retainers (3) to the crossmember. Tighten all four stabilizer bar cushion retainer screws to 30 Nm (22 ft. lbs.). 10. Attach the stabilizer bar link (1) at each end of the stabilizer bar (2). At each link, install and tighten the nut (3) while holding the stabilizer bar link lower stud stationary. Tighten the nuts to 58 Nm (43 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front Suspension > Page 6898 11. Position the power steering hose routing clamps (2) on the crossmember. Install the fasteners. Tighten the screw to 8 Nm (71 in. lbs.). 12. Install the rear engine mount. 13. If equipped, install the engine belly pan. 14. Lower the vehicle. 15. Perform wheel alignment as necessary paying special attention to front camber and caster. The crossmember may need to be shifted on its mounts slightly to gain preferred setting. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front Suspension > Page 6899 Stabilizer Bar: Service and Repair Rear Suspension Removal REMOVAL NOTE: Before proceeding, refer to REAR SUSPENSION WARNING. 1. Raise and support the vehicle. 2. On both sides of the vehicle, while holding the stabilizer bar link upper stud stationary, remove the nut (1) securing the link to the stabilizer bar (3). 3. If equipped with all-wheel-drive, remove the rear driveline module. 4. On both sides of the vehicle, remove the screws (3) securing the stabilizer bushing retainers (1) to the crossmember. 5. Remove the two stabilizer bushing retainers. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front Suspension > Page 6900 6. Remove the stabilizer bar (2) from the vehicle. 7. If required, remove the two cushions from the stabilizer bar utilizing the slit cut into the cushions (bushings). Installation INSTALLATION 1. If required, install the two cushions on the stabilizer bar (one on each side) utilizing the slit cut into the cushions (bushings). NOTE: When installing the stabilizer bar on a vehicle with all-wheel-drive, position the bar so that the bar loops under the axle half shafts once installed, not over the axle half shafts. 2. Position the stabilizer bar (2) on the rear crossmember. 3. Install the two retainers (1) over the cushions at the mounting holes and install the retainer screws (3). Do not tighten the screws at this time. 4. If equipped with all-wheel-drive, install the rear driveline module. 5. On each side of the vehicle, install the stabilizer link upper stud in the end of the stabilizer bar (3). Install the nut (1) on each upper stud and while holding the stabilizer link stud stationary, tighten the nut (2) to 58 Nm (43 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front Suspension > Page 6901 6. Tighten the cushion retainer screws to 34 Nm (25 ft. lbs.). 7. Lower the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest for Suspension Strut / Shock Absorber: > 02-001-09 > Aug > 09 > Suspension - Rough Handling/Front Strut(s) Leaking Suspension Strut / Shock Absorber: Customer Interest Suspension - Rough Handling/Front Strut(s) Leaking NUMBER: 02-001-09 GROUP: Springs/Shocks DATE: August 08, 2009 SUBJECT: Poor Handling and/or Strut Leaking and/or Rides Rough OVERVIEW: This bulletin involves replacing the, jounce bumper and dust shield with a new design if front struts are replaced due to degraded performance. MODELS: 2007-2009 (PM) Caliber 2007-2009 (MK) Compass/Patriot NOTE: This Bulletin applies to vehicles built before April 23, 2009 (MDH 0423XX). SYMPTOM/CONDITION: The front strut(s) leaking and/or the vehicle handles rough. DISCUSSION: When replacing front struts due to degraded performance. The jounce bumper/dust shield must be replaced with the latest design. Perform the inspection/repair procedure to determine if jounce bumper/dust shield requires replacement SPECIAL TOOLS/EQUIPMENT REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest for Suspension Strut / Shock Absorber: > 02-001-09 > Aug > 09 > Suspension - Rough Handling/Front Strut(s) Leaking > Page 6910 PARTS REQUIRED: REPAIR PROCEDURE: 1. Is the jounce bumper and dust shield a one-piece black rubber part? a. Yes >> Proceed to b. No >> This bulletin does not apply the latest part design has been implemented. 2. Remove both right and left front struts. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 2-Front Suspension > STRUT, Suspension, Assembly > Removal. NOTE: Even though one front strut needs replacement both jounce bumper/dust shields require replacement. 3. Disassemble the undamaged strut assembly. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 2-Front Suspension > STRUT, Suspension, Assembly> Disassembly. 4. Remove the undamaged front strut assembly jounce bumper. 5. Install jounce bumper(s) p/n 05171137AB on the replacement and undamaged front strut assembly. 6. Install dust shield cover(s) p/n 05171132AC on both the strut assemblies. 7. Assemble the strut assemblies. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 2-Front Suspension > STRUT, Suspension, Assembly > Assembly. 8. Install the strut assemblies. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 2-Front Suspension > STRUT, Suspension, Assembly > Installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest for Suspension Strut / Shock Absorber: > 02-001-09 > Aug > 09 > Suspension - Rough Handling/Front Strut(s) Leaking > Page 6911 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest for Suspension Strut / Shock Absorber: > 02-001-06 > Oct > 06 > Suspension - Swish Sound From Rear of Vehicle On Bumps Suspension Strut / Shock Absorber: Customer Interest Suspension - Swish Sound From Rear of Vehicle On Bumps NUMBER: 02-001-06 GROUP: Suspension DATE: October 20, 2006 SUBJECT: Swish Sound Heard From Rear Of Vehicle Over Low Speed Bumps OVERVIEW: This bulletin involves installing a shock cap on both rear shocks. MODELS: 2007 (MK-49) Compass 2007 (PM) Caliber NOTE: This bulletin applies to vehicles built prior to October 6, 2006 (MDH 0606XX). SYMPTOM/CONDITION: Swish sound heard from the rear of the vehicle. This condition is more noticeable when the vehicle is traveling over a bumpy road or speed bumps at low speeds. DIAGNOSIS: Drive vehicle over speed bumps or a bumpy road a low speeds. If the swish sound can be heard, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove both rear shocks using the procedures available in TechCONNECT, Refer to 2 Suspension/Rear/Shock - Removal. NOTE: Be sure to clearly mark right and left shock for re-installation. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest for Suspension Strut / Shock Absorber: > 02-001-06 > Oct > 06 > Suspension - Swish Sound From Rear of Vehicle On Bumps > Page 6916 2. Install the shock cap (p/n 05105949AA) over the top of both shocks (2) (Fig. 1). 3. Install both rear shocks using the procedures available in TechCONNECT, Refer to 2 Suspension/Rear/Shock - Installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 02-001-09 > Aug > 09 > Suspension - Rough Handling/Front Strut(s) Leaking Suspension Strut / Shock Absorber: All Technical Service Bulletins Suspension - Rough Handling/Front Strut(s) Leaking NUMBER: 02-001-09 GROUP: Springs/Shocks DATE: August 08, 2009 SUBJECT: Poor Handling and/or Strut Leaking and/or Rides Rough OVERVIEW: This bulletin involves replacing the, jounce bumper and dust shield with a new design if front struts are replaced due to degraded performance. MODELS: 2007-2009 (PM) Caliber 2007-2009 (MK) Compass/Patriot NOTE: This Bulletin applies to vehicles built before April 23, 2009 (MDH 0423XX). SYMPTOM/CONDITION: The front strut(s) leaking and/or the vehicle handles rough. DISCUSSION: When replacing front struts due to degraded performance. The jounce bumper/dust shield must be replaced with the latest design. Perform the inspection/repair procedure to determine if jounce bumper/dust shield requires replacement SPECIAL TOOLS/EQUIPMENT REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 02-001-09 > Aug > 09 > Suspension - Rough Handling/Front Strut(s) Leaking > Page 6922 PARTS REQUIRED: REPAIR PROCEDURE: 1. Is the jounce bumper and dust shield a one-piece black rubber part? a. Yes >> Proceed to b. No >> This bulletin does not apply the latest part design has been implemented. 2. Remove both right and left front struts. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 2-Front Suspension > STRUT, Suspension, Assembly > Removal. NOTE: Even though one front strut needs replacement both jounce bumper/dust shields require replacement. 3. Disassemble the undamaged strut assembly. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 2-Front Suspension > STRUT, Suspension, Assembly> Disassembly. 4. Remove the undamaged front strut assembly jounce bumper. 5. Install jounce bumper(s) p/n 05171137AB on the replacement and undamaged front strut assembly. 6. Install dust shield cover(s) p/n 05171132AC on both the strut assemblies. 7. Assemble the strut assemblies. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 2-Front Suspension > STRUT, Suspension, Assembly > Assembly. 8. Install the strut assemblies. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 2-Front Suspension > STRUT, Suspension, Assembly > Installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 02-001-09 > Aug > 09 > Suspension - Rough Handling/Front Strut(s) Leaking > Page 6923 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 02-001-06 > Oct > 06 > Suspension - Swish Sound From Rear of Vehicle On Bumps Suspension Strut / Shock Absorber: All Technical Service Bulletins Suspension - Swish Sound From Rear of Vehicle On Bumps NUMBER: 02-001-06 GROUP: Suspension DATE: October 20, 2006 SUBJECT: Swish Sound Heard From Rear Of Vehicle Over Low Speed Bumps OVERVIEW: This bulletin involves installing a shock cap on both rear shocks. MODELS: 2007 (MK-49) Compass 2007 (PM) Caliber NOTE: This bulletin applies to vehicles built prior to October 6, 2006 (MDH 0606XX). SYMPTOM/CONDITION: Swish sound heard from the rear of the vehicle. This condition is more noticeable when the vehicle is traveling over a bumpy road or speed bumps at low speeds. DIAGNOSIS: Drive vehicle over speed bumps or a bumpy road a low speeds. If the swish sound can be heard, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove both rear shocks using the procedures available in TechCONNECT, Refer to 2 Suspension/Rear/Shock - Removal. NOTE: Be sure to clearly mark right and left shock for re-installation. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 02-001-06 > Oct > 06 > Suspension - Swish Sound From Rear of Vehicle On Bumps > Page 6928 2. Install the shock cap (p/n 05105949AA) over the top of both shocks (2) (Fig. 1). 3. Install both rear shocks using the procedures available in TechCONNECT, Refer to 2 Suspension/Rear/Shock - Installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Front Suspension Suspension Strut / Shock Absorber: Description and Operation Front Suspension Description DESCRIPTION A MacPherson type design strut assembly is used in place of the front suspension upper control arm and upper ball joint. The bottom of the strut mounts directly to the steering knuckle using two attaching bolts and nuts going through the strut clevis bracket and knuckle. The top of the strut mounts directly to the strut tower of the vehicle using the three threaded studs on the strut assembly's upper mount. The strut assembly includes the following components: - Upper mount (rubber isolated) (2) - Bearing (3) - Upper spring seat and isolator (4) - Coil spring (5) - Dust shield and jounce bumper (6) - Lower spring isolator (7) - Strut (damper) (8) Each component is serviced by removing the strut assembly from the vehicle and disassembling it. Coil springs are rated separately for each corner or side of the vehicle depending on optional equipment and type of vehicle service. If a coil spring requires replacement, be sure that it is replaced with a spring meeting the correct load rating for the vehicle and its specific options. Operation OPERATION The strut assembly cushions the ride of the vehicle, controlling vibration, jounce and rebound of the suspension. The coil spring controls ride quality and maintains proper ride height. The spring isolators isolate the coil spring at the top and bottom from coming into metal-to-metal contact with the upper mounting seat and the strut. The jounce bumper limits suspension travel and metal-to-metal contact under full jounce condition. The strut dampens jounce and rebound motions of the coil spring and suspension. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Front Suspension > Page 6931 Suspension Strut / Shock Absorber: Description and Operation Rear Suspension DESCRIPTION A coil-over shock absorber assembly supports each side of the vehicle. The bottom of the shock assembly mounts to the lower control arm. The top of the shock assembly mounts to the body. The shock assembly includes the following major components: - Upper bushing (3) - Upper mounting bracket (4) - Upper spring isolator (5) - Sleeve (6) - Lower bushing (7) - Jounce bumper (9) - Dust shield (10) - Coil spring (11) - Lower spring isolator (12) - Shock absorber (13) Later build vehicles also have a noise abatement cap located on top of the assembly. Each component is serviced by removing the shock assembly from the vehicle and disassembling it. Coil springs are rated separately for each corner or side of the vehicle depending on optional equipment and type of vehicle service. If a coil spring requires replacement, be sure that it is replaced with a spring meeting the correct load rating for the vehicle and its specific options. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Front Suspension Suspension Strut / Shock Absorber: Testing and Inspection Front Suspension STRUT ASSEMBLY Inspect the strut assembly for the following conditions: - Inspect for a damaged or broken coil spring (5). - Inspect for a torn or damaged dust shield (6). - Lift the dust shield and inspect the strut assembly for evidence of fluid running from the upper end of the strut fluid reservoir. (Actual leakage will be a stream of fluid running down the side and dripping off lower end of unit). A slight amount of seepage between the strut shaft and strut shaft seal is not unusual and does not affect performance of the strut assembly. - Inspect the jounce bumper for signs of damage or deterioration. - Inspect the clearance between the shock tower and the coil spring. Make sure no fasteners are protruding through the shock tower possibly contacting the coil spring and strut. Because of the minimum clearance in this area, installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. CAUTION: At no time when servicing a vehicle can a sheet metal screw, bolt or other metal fastener be installed into the strut tower (1) to take the place of an original plastic clip. Also, do not drill holes into the front strut tower for the installation of any metal fasteners into Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Front Suspension > Page 6934 the shock tower area indicated (3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Front Suspension > Page 6935 Suspension Strut / Shock Absorber: Testing and Inspection Rear Suspension SHOCK ABSORBER Inspect the shock absorber for damage and evidence of fluid running from the upper end of the fluid reservoir. (Actual leakage will be a stream of fluid running down the side of the reservoir tube and dripping off lower end of unit). A slight amount of seepage between the shaft and shaft seal is not unusual and does not affect performance of the shock absorber. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Strut / Shock Suspension Strut / Shock Absorber: Service and Repair Front Strut / Shock Removal REMOVAL NOTE: Before proceeding, refer to FRONT SUSPENSION WARNING. 1. Raise and support the vehicle. 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). NOTE: If both strut assemblies are to be removed, mark the strut assemblies right or left and keep the parts separated to avoid mix-up. Not all parts of the strut assembly are interchangeable side-to-side. 3. Remove the screw (1) securing the flex hose (2) routing bracket to the strut (6). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Strut / Shock > Page 6938 4. While holding the stabilizer bar link (1) stud stationary, remove the nut (4) securing the link to the strut (3). CAUTION: The strut assembly-to-knuckle attaching bolts (5) are serrated and must not be turned during removal. Hold the bolts stationary in the knuckle while removing the nuts, then tap the bolts out using a pin punch. 5. While holding the bolt heads stationary, remove the two nuts (2) from the bolts (5) attaching the strut (3) to the knuckle (6). 6. Remove the two bolts (5) attaching the strut (3) to the knuckle (6) using a pin punch. 7. Lower the vehicle just enough to open the hood without allowing the tires to touch the floor. 8. Remove the three nuts (1) attaching the strut assembly (2) upper mount to the strut tower. 9. Remove the strut assembly (2) from the vehicle. 10. For disassembly, refer to Front Suspension Strut Disassembly. Disassembly DISASSEMBLY NOTE: The strut assembly must be removed from the vehicle for it to be disassembled and assembled. For the disassembly and assembly of the strut assembly, use strut spring compressor, teamPSE tool 223-7400, or the equivalent, to compress the coil spring. Follow the manufacturer's instructions closely. WARNING: Do not remove the strut rod nut before the coil spring is properly compressed. The coil spring is held under pressure. The coil Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Strut / Shock > Page 6939 spring must be compressed, removing spring tension from the upper mount and bearing, before the strut rod nut is removed. 1. If both struts are being serviced at the same time, mark both the coil spring and strut assembly according to which side of the vehicle the strut is being removed from. 2. Position the strut assembly (2) in the strut coil spring compressor (1) following the manufacturer's instructions and set the lower and upper hooks of the compressor on the coil spring. Position the strut clevis bracket (2) straight outward, away from the compressor. 3. Compress the coil spring until all coil spring tension is removed from the upper mount and bearing. CAUTION: Never use impact or high speed tools to remove the strut rod nut. Damage to the strut internal bearings can occur. 4. Once the spring is sufficiently compressed, install Strut Nut Wrench (2), Special Tool 9362, on the strut rod nut. Next, install Strut Shaft Socket (1), Special Tool 9894, on the end of the strut rod. While holding the strut rod from turning, remove the nut using the strut nut wrench. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Strut / Shock > Page 6940 5. Remove the clamp (if installed) from the bottom of the coil spring and remove the strut (damper) (8) out through the bottom of the coil spring. The dust shield and jounce bumper will come out with the strut. 6. Remove the lower spring isolator (7) from the strut seat. 7. Slide the dust shield and jounce bumper (6) from the strut rod. 8. Remove the upper mount (2) and bearing (3) from the top of the upper spring seat and isolator (4). 9. Remove the upper spring seat and isolator (4) from the top of the coil spring (5). NOTE: If the coil spring needs to be serviced, proceed with the next step, otherwise, proceed with STEP 11. 10. Release the tension from the coil spring by backing off the compressor drive completely. Push back the compressor hooks and remove the coil spring. 11. Inspect the strut assembly components for the following and replace as necessary: - Inspect the strut (damper) (8) for shaft binding over the full stroke of the shaft. - Inspect the jounce bumper (with dust shield) (6) for cracks and signs of deterioration. - Check the upper mount (2) for cracks and distortion and its retaining studs for any sign of damage. - Check the bearing (3) for any binding. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Strut / Shock > Page 6941 - Check the upper spring seat and isolator (4) for cracks and distortion. - Inspect the upper and lower spring isolators (4, 7) for material deterioration and distortion. - Inspect the coil spring (5) for any sign of damage to the coating. NOTE: For reassembly, refer to Front Suspension Strut Assembly. Assembly ASSEMBLY NOTE: If the coil spring has been removed from the spring compressor, proceed with the next step, otherwise, proceed with STEP 3. CAUTION: When installing the coil spring, make sure the end with the ID tag is placed downward, otherwise spring-to-body contact will occur after strut assembly installation. 1. Place the coil spring in the spring compressor following the manufacturer's instructions. Before compressing the spring, rotate the spring so the end of the bottom coil is at approximately the 9 o'clock position as viewed above (or to where the spring was when removed from the compressor). This action will allow the strut (damper) clevis bracket to be positioned outward, away from the compressor once installed. 2. Slowly compress the coil spring until enough room is available for strut assembly reassembly. 3. Install the upper spring seat and isolator (4) on top of the coil spring (5). 4. Install the bearing (3) and upper mount (2) on top of the upper spring seat and isolator (4). 5. Install the lower spring isolator (7) on the spring seat on the strut (8). 6. Slide the dust shield and jounce bumper (6) onto the strut rod. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Strut / Shock > Page 6942 7. Install the strut up through the bottom of the coil spring and upper spring seat, mount, and bearing until the lower spring seat contacts the lower end of the coil spring. Rotate the strut as necessary until the end of the bottom coil (2) comes in contact with the stop (1) built into the lower spring isolator. 8. While holding the strut in position, install the nut (1) on the end of the strut rod. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Strut / Shock > Page 6943 CAUTION: Never use impact or high speed tools to remove the strut rod nut. Damage to the strut internal bearings can occur. 9. Install Strut Nut Wrench (2), Special Tool 9362, on the strut rod nut. Next, install Strut Shaft Socket (1), Special Tool 9894, on the end of the strut rod. While holding the strut rod from turning, tighten the strut rod nut to 60 Nm (44 ft. lbs.) using a torque wrench on the end of Special Tool 9362. 10. Slowly release the tension from the coil spring by backing off the compressor (1) drive completely. As the tension is relieved, make sure the upper mount and bearing align properly. Verify the upper mount does not bind when rotated. 11. Remove the strut assembly from the spring compressor. 12. Install the strut assembly on the vehicle. Installation INSTALLATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Strut / Shock > Page 6944 1. Raise the strut assembly (2) into the strut tower, aligning the three studs on the strut assembly upper mount with the holes in strut tower. Install the three mounting nuts (1) on the studs. Tighten the three nuts to 48 Nm (35 ft. lbs.). CAUTION: The strut assembly-to-knuckle attaching bolts (5) are serrated and must not be turned during installation. Install the nuts while holding the bolts stationary in the knuckle. 2. Position the lower end of the strut assembly (3) in line with the upper end of the knuckle (6), aligning the mounting holes. Install the two attaching bolts (5). Install the nuts (2). While holding the bolts in place, tighten the nuts to 84 Nm (62 ft. lbs.). 3. Attach the stabilizer bar link (1) to the strut (3). Install and tighten the nut (4) while holding the stabilizer bar link stud stationary. Tighten the nut to 58 Nm (43 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Strut / Shock > Page 6945 4. Secure the flex hose (2) routing bracket to the strut (6) with the mounting screw (1). Tighten the mounting screw to 13 Nm (120 in. lbs.). 5. Install tire and wheel assembly (1). Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 6. Lower the vehicle. 7. Perform wheel alignment as necessary. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Strut / Shock > Page 6946 Suspension Strut / Shock Absorber: Service and Repair Rear Shock Absorber Removal REMOVAL NOTE: Before proceeding, refer to REAR SUSPENSION WARNING. 1. Remove the interior rear quarter trim panel. 2. Remove the two nuts (1) securing the shock assembly (2) to the body bracket (3). 3. Raise and support the vehicle. 4. Remove the wheel mounting nuts (3), then the rear tire and wheel assembly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Strut / Shock > Page 6947 5. Remove the shock lower mounting nut (3) and bolt (1). 6. Lower the shock assembly (2) out of the body bracket (1) and lift out over rear suspension. Disassembly DISASSEMBLY NOTE: The shock assembly must be removed from the vehicle for it to be disassembled and assembled. For the disassembly and assembly of the shock assembly, use Strut Spring Compressor, teamPSE tool 223-7400, or the equivalent, to compress the coil spring. Follow the manufacturer's instructions closely. WARNING: Do not remove the shock rod nut before the coil spring is properly compressed. The coil spring is held under pressure. The coil spring must be compressed, removing spring tension from the upper mounting bracket, before the shock rod nut is removed. 1. If both shocks are being serviced at the same time, mark both the coil spring and shock assembly according to which side of the vehicle the shock is being removed from. 2. If equipped, remove the noise abatement cap from top of the shock assembly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Strut / Shock > Page 6948 3. Position the shock assembly (2) in the strut spring compressor (1) following the manufacturer's instructions and set the lower and upper hooks of the compressor on the coil spring. 4. Compress the coil spring until all spring tension is removed from the upper mounting bracket and bushings. CAUTION: Never use impact or high speed tools to remove the shock rod nut. Damage to the shock internal bearings can occur. 5. Once the spring is sufficiently compressed, install Snap-On(R) Shock Absorber Socket A139, or equivalent, on the end of the shock rod (1). While holding the shock rod from turning, remove the nut (2) using a wrench. Remove the washer below the nut. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Strut / Shock > Page 6949 6. Remove the shock absorber (13) out through the bottom of the coil spring (11). The washer (8), jounce bumper (9), dust shield (10) and lower spring isolator (12) will come out with the shock. 7. Slide the washer (8), jounce bumper (9), dust shield (10) from the shock rod. 8. Remove the lower spring isolator (12) from the shock spring seat. 9. Remove the upper mounting bracket (4), bushings (3, 7), sleeve (6) and upper spring isolator (5) from the top of the spring. 10. Remove the bushings (3, 7), sleeve (6) and upper spring isolator (5) from the upper mounting bracket (4). NOTE: If the coil spring needs to be serviced, proceed with the next step, otherwise, proceed with STEP 12. 11. Release the tension from the coil spring by backing off the compressor drive completely. Push back the compressor hooks and remove the coil spring. 12. Inspect the shock assembly components for the following and replace as necessary: - Inspect the shock (13) for shaft binding over the full stroke of the shaft. - Inspect the jounce bumper (9) for cracks and signs of deterioration. - Inspect the dust shield (10) for cracks and tears. - Check the upper mounting bracket (4) for cracks and distortion and its retaining studs for any sign of damage. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Strut / Shock > Page 6950 - Inspect the upper (3) and lower (7) bushings, for material deterioration and signs of deterioration. Inspect the sleeve (6) for wear and distortion. - Inspect the upper (5) and lower (12) spring isolators for material deterioration and distortion. - Inspect the coil spring (11) for any sign of damage to the coating. NOTE: For reassembly, refer to REAR SUSPENSION SHOCK ASSEMBLY. Assembly ASSEMBLY NOTE: If the coil spring has been removed from the spring compressor, proceed with the next step, otherwise, proceed with STEP 3. CAUTION: When installing the coil spring, make sure the end with the ID tag is placed upward, otherwise spring-to-body contact will occur after shock assembly installation. 1. Place the coil spring in the spring compressor following the manufacturer's instructions. 2. Slowly compress the coil spring until enough room is available for shock assembly reassembly. 3. Assemble the bushings (3, 7) and sleeve (6) through the upper mounting bracket (4). 4. Install the upper spring isolator (5) on the upper mounting bracket (4). 5. Install the upper mounting bracket (4) on top of the coil spring. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Strut / Shock > Page 6951 6. Install the lower spring isolator (12) on the spring seat of the shock absorber (13). 7. Slide the dust shield (10), jounce bumper (9) and washer (8) onto the shock rod. 8. Install the shock absorber (13) up through the bottom of the coil spring and upper mounting bracket until the lower spring seat contacts the lower end of the coil spring. 9. While holding the shock absorber in position, install the washer (2) and nut (1) on the end of the shock rod. CAUTION: Never use impact or high speed tools to remove the shock rod nut. Damage to the shock internal bearings can occur. 10. Install Snap-On(R) Shock Absorber Socket A139, or equivalent, on the end of the shock rod (1). While holding the shock rod from turning, tighten the nut (2) using a crows foot wrench and a torque wrench. Tighten the shock rod nut to 24 Nm (18 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Strut / Shock > Page 6952 11. Turn the upper mounting bracket or shock absorber as necessary until the mounting studs on the mounting bracket line up with the lower mounting bolt eyelet at the bottom of the shock absorber. 12. Slowly release the tension from the coil spring by backing off the compressor (1) drive completely. 13. Remove the shock assembly from the spring compressor. 14. If equipped, install the noise abatement cap on top of the shock assembly. 15. Install the shock assembly on the vehicle. Installation INSTALLATION 1. Insert the lower end of the shock assembly (2) down though the lower control arm from above just enough to clear the body, then lift it up into the body bracket (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Strut / Shock > Page 6953 2. Install the mounting bolt (1) and nut (3) fastening the shock assembly (2) to the lower control arm (4). Do not tighten at this time. 3. Install the tire and wheel assembly (1). Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 4. Lower the vehicle. 5. install the two nuts (1) securing the shock assembly (2) to the body bracket (3). Tighten the mounting nuts to 48 Nm (35 ft. lbs.). 6. Install the interior rear quarter trim panel. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Strut / Shock > Page 6954 7. Position the vehicle on an alignment rack/drive-on lift. Raise the lift as necessary to access the shock mounting bolt (1) and nut (3). 8. Tighten the shock assembly lower mounting bolt nut (3) to 99 Nm (73 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Technical Service Bulletins > Customer Interest for Suspension Travel Bumper: > 02-001-09 > Aug > 09 > Suspension - Rough Handling/Front Strut(s) Leaking Suspension Travel Bumper: Customer Interest Suspension - Rough Handling/Front Strut(s) Leaking NUMBER: 02-001-09 GROUP: Springs/Shocks DATE: August 08, 2009 SUBJECT: Poor Handling and/or Strut Leaking and/or Rides Rough OVERVIEW: This bulletin involves replacing the, jounce bumper and dust shield with a new design if front struts are replaced due to degraded performance. MODELS: 2007-2009 (PM) Caliber 2007-2009 (MK) Compass/Patriot NOTE: This Bulletin applies to vehicles built before April 23, 2009 (MDH 0423XX). SYMPTOM/CONDITION: The front strut(s) leaking and/or the vehicle handles rough. DISCUSSION: When replacing front struts due to degraded performance. The jounce bumper/dust shield must be replaced with the latest design. Perform the inspection/repair procedure to determine if jounce bumper/dust shield requires replacement SPECIAL TOOLS/EQUIPMENT REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Technical Service Bulletins > Customer Interest for Suspension Travel Bumper: > 02-001-09 > Aug > 09 > Suspension - Rough Handling/Front Strut(s) Leaking > Page 6963 PARTS REQUIRED: REPAIR PROCEDURE: 1. Is the jounce bumper and dust shield a one-piece black rubber part? a. Yes >> Proceed to b. No >> This bulletin does not apply the latest part design has been implemented. 2. Remove both right and left front struts. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 2-Front Suspension > STRUT, Suspension, Assembly > Removal. NOTE: Even though one front strut needs replacement both jounce bumper/dust shields require replacement. 3. Disassemble the undamaged strut assembly. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 2-Front Suspension > STRUT, Suspension, Assembly> Disassembly. 4. Remove the undamaged front strut assembly jounce bumper. 5. Install jounce bumper(s) p/n 05171137AB on the replacement and undamaged front strut assembly. 6. Install dust shield cover(s) p/n 05171132AC on both the strut assemblies. 7. Assemble the strut assemblies. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 2-Front Suspension > STRUT, Suspension, Assembly > Assembly. 8. Install the strut assemblies. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 2-Front Suspension > STRUT, Suspension, Assembly > Installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Technical Service Bulletins > Customer Interest for Suspension Travel Bumper: > 02-001-09 > Aug > 09 > Suspension - Rough Handling/Front Strut(s) Leaking > Page 6964 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Travel Bumper: > 02-001-09 > Aug > 09 > Suspension - Rough Handling/Front Strut(s) Leaking Suspension Travel Bumper: All Technical Service Bulletins Suspension - Rough Handling/Front Strut(s) Leaking NUMBER: 02-001-09 GROUP: Springs/Shocks DATE: August 08, 2009 SUBJECT: Poor Handling and/or Strut Leaking and/or Rides Rough OVERVIEW: This bulletin involves replacing the, jounce bumper and dust shield with a new design if front struts are replaced due to degraded performance. MODELS: 2007-2009 (PM) Caliber 2007-2009 (MK) Compass/Patriot NOTE: This Bulletin applies to vehicles built before April 23, 2009 (MDH 0423XX). SYMPTOM/CONDITION: The front strut(s) leaking and/or the vehicle handles rough. DISCUSSION: When replacing front struts due to degraded performance. The jounce bumper/dust shield must be replaced with the latest design. Perform the inspection/repair procedure to determine if jounce bumper/dust shield requires replacement SPECIAL TOOLS/EQUIPMENT REQUIRED: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Travel Bumper: > 02-001-09 > Aug > 09 > Suspension - Rough Handling/Front Strut(s) Leaking > Page 6970 PARTS REQUIRED: REPAIR PROCEDURE: 1. Is the jounce bumper and dust shield a one-piece black rubber part? a. Yes >> Proceed to b. No >> This bulletin does not apply the latest part design has been implemented. 2. Remove both right and left front struts. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 2-Front Suspension > STRUT, Suspension, Assembly > Removal. NOTE: Even though one front strut needs replacement both jounce bumper/dust shields require replacement. 3. Disassemble the undamaged strut assembly. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 2-Front Suspension > STRUT, Suspension, Assembly> Disassembly. 4. Remove the undamaged front strut assembly jounce bumper. 5. Install jounce bumper(s) p/n 05171137AB on the replacement and undamaged front strut assembly. 6. Install dust shield cover(s) p/n 05171132AC on both the strut assemblies. 7. Assemble the strut assemblies. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 2-Front Suspension > STRUT, Suspension, Assembly > Assembly. 8. Install the strut assemblies. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 2-Front Suspension > STRUT, Suspension, Assembly > Installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Travel Bumper: > 02-001-09 > Aug > 09 > Suspension - Rough Handling/Front Strut(s) Leaking > Page 6971 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service and Repair > Removal Trailing Arm: Service and Repair Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). 3. Remove the screw (2) securing the brake flex hose (1) to the trailing link (3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service and Repair > Removal > Page 6976 4. Remove the nut (1) securing the brake tube routing bracket to the trailing link. 5. Remove the brake tube (3) from the routing clip (2) on the trailing link. 6. Remove the two bolts (1) securing disc brake caliper adapter (3) to the brake support plate (4). 7. Remove the disc brake caliper (2) and adapter (3) as an assembly. Hang the assembly out of the way using wire or a bungee cord. Use care not to overextend the brake hose and tubing when doing this. 8. If equipped, remove the screw (4) fastening the wheel speed sensor (3) to the trailing link (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service and Repair > Removal > Page 6977 9. If equipped, remove the routing clip (1) fastening the wheel speed sensor (3) to the trailing link (2). 10. Remove the brake rotor, then hub and bearing. 11. Remove the parking brake cable from the lever on the parking brake shoe. 12. Remove the hair pin (1) securing the parking brake cable (2) to the brake support plate (3). 13. Slide the brake support plate (3) with parking brake shoes off the end of the parking brake cable (2) and remove. 14. Pull the parking brake cable from the trailing link. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service and Repair > Removal > Page 6978 15. Remove the bolt (2) securing the toe link (3) to the trailing link. 16. Remove the nut (2) and bolt securing the lower control arm to the trailing link (3). 17. Remove the nut (1) and bolt securing the upper control arm to the trailing link (3). 18. Remove the two bolts (2) fastening the leading end of the trailing link (3) to the body (1). 19. Remove the trailing link. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service and Repair > Removal > Page 6979 Trailing Arm: Service and Repair Installation INSTALLATION 1. Position the trailing link and install the two bolts (2) fastening the leading end of the trailing link (3) to the body (1). Tighten the two mounting bolts to 60 Nm (44 ft. lbs.). 2. Position the upper control arm on the trailing link (3) and install the bolt and nut (1) securing the arm to the link. Tighten the mounting bolt nut to 95 Nm (70 ft. lbs.). 3. Position the lower control arm on the trailing link (3) and install the bolt and nut (2) securing the arm to the link. Tighten the mounting bolt nut to 95 Nm (70 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service and Repair > Removal > Page 6980 4. Install the bolt (2) securing the toe link to the trailing link. To install the bolt it may be necessary to flex the trailing link body mount bushing inward or outward using an appropriate prying tool. Tighten the mounting bolt to 95 Nm (70 ft. lbs.). 5. Insert the parking brake cable through the trailing link from the inboard side. 6. Slide the parking brake cable (2) into the brake support plate (3) with parking brake shoes. 7. Install the hair pin (1) securing the parking brake cable (2) to the brake support plate (3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service and Repair > Removal > Page 6981 8. Install the parking brake cable onto the lever on the parking brake shoe. 9. If equipped, position the wheel speed sensor (3) and install the screw (4) fastening the sensor to the trailing link (2). Tighten the mounting screw to 18 Nm (13 ft. lbs.). 10. If equipped, position the wheel speed sensor (3) and install the routing clip (1) fastening the sensor to the trailing link (2). 11. Install the hub and bearing, then install the brake rotor onto the wheel studs. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service and Repair > Removal > Page 6982 12. Slide the disc brake caliper (2) and adapter (3) assembly over brake rotor and brake support plate. 13. Install the two bolts (1) securing disc brake caliper adapter (3) to the brake support plate (4). Tighten the mounting bolts to 71 Nm (52 ft. lbs.). 14. Position the brake tube on the trailing link inserting the tube into the routing clip (2) and routing bracket over the welded stud. 15. Install the nut (1) on the welded stud. Tighten the nut to 15 Nm (11 ft. lbs.). 16. Position the brake flex hose (1) at the trailing link (3) bracket and install the mounting screw (2). Tighten the screw to 23 Nm (17 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service and Repair > Removal > Page 6983 17. Install tire and wheel assembly (1). Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 18. Lower the vehicle. 19. Perform wheel alignment as necessary. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Description and Operation > Front Suspension Wheel Bearing: Description and Operation Front Suspension DESCRIPTION The wheel bearing (5) and hub (3) are pressed into the knuckle (1). The wheel bearing is secured in place using a snap ring. One side of the wheel bearing has an integrated magnetic encoder ring for wheel speed sensor usage as equipped. It is important that the wheel speed sensor magnetic encoder ring (dark band) (3) be positioned to the inside of the knuckle or the wheel speed sensor will not operate correctly. The wheel bearing is a Unit 1 type cartridge bearing that requires no maintenance. The wheel bearing can be serviced separately from the hub. The hub supports the driveline halfshaft outer constant velocity (C/V) joint. Each is splined and meshes in the center of the hub. The outer C/V joint is retained to the hub using a nut. The nut is locked to the outer C/V stub shaft using a cotter pin. The hub has five studs pressed into its flange. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Description and Operation > Front Suspension > Page 6988 Wheel Bearing: Description and Operation Rear Suspension DESCRIPTION The rear wheel bearing and wheel mounting hub used on this vehicle are a one-piece sealed unit or hub and bearing assembly. It is permanently lubricated when assembled and is sealed for life. There is no periodic lubrication or maintenance recommended for these units. The hub and bearing (5) is mounted to the trailing link (1). All vehicles have a magnetic encoder integrated into the right rear hub and bearing for speed sense. Vehicles equipped with antilock brakes have a magnetic encoder integrated into both rear hub and bearings. The encoder works with the rear wheel speed sensors to provide wheel speed signal. The sensor mounts by screw to the rear of the front-wheel-drive hub and bearing while the sensor clips to the rear of the all-wheel-drive hub and bearing. The only serviceable components of the hub and bearing are the wheel mounting studs pressed into the hub. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Front Suspension Wheel Bearing: Testing and Inspection Front Suspension WHEEL BEARING AND HUB NOTE: The wheel bearing is designed to last for the life of the vehicle and requires no type of periodic maintenance. The following procedure may be used for diagnosing the condition of the wheel bearing and hub. 1. Remove the wheel and tire assembly, disc brake caliper and brake rotor. 2. Rotate the wheel hub checking for resistance or roughness. Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing. If the bearing exhibits any of these conditions, the hub bearing will require replacement. Do not attempt to disassemble the bearing for repair. If the wheel bearing is disassembled for any reason, it must be replaced. Damaged bearing seals and the resulting excessive grease loss may also require bearing replacement. Moderate grease weeping from the bearing is considered normal and should not require replacement of the wheel bearing. To diagnose a bent hub, measure hub runout. Refer to Brakes and Traction Control/Testing and inspection. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Front Suspension > Page 6991 Wheel Bearing: Testing and Inspection Rear Suspension HUB AND BEARING NOTE: The wheel bearing is designed to last for the life of the vehicle and requires no type of periodic maintenance. The following procedure may be used for diagnosing the condition of the wheel bearing and hub. 1. Remove the wheel and tire assembly, disc brake caliper and brake rotor. 2. Rotate the wheel hub checking for resistance or roughness. Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing. If the bearing exhibits any of these conditions, the hub and bearing will require replacement. Do not attempt to disassemble the bearing for repair. If the wheel bearing is disassembled for any reason, it must be replaced. Damaged bearing seals and the resulting excessive grease loss may also require bearing replacement. Moderate grease seepage from the bearing is considered normal and should not require replacement of the wheel bearing. To diagnose a bent hub, measure hub runout. Refer to Brakes and Traction Control/Testing and Inspection. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension Wheel Bearing: Service and Repair Front Suspension Removal REMOVAL NOTE: The removal and installation of the wheel bearing and hub from the knuckle is only to be done with the knuckle removed from the vehicle. 1. Remove the steering knuckle from the vehicle. 2. Position the locator block (2) for Fixture, Special Tool 9712, as follows: a. For left side knuckles, place the locator block (2) to the left side (4) on the Fixture. The side of the locator block with the angle cut goes downward, toward the Fixture. Install the mounting screws and tighten them to approximately 54 Nm (40 ft. lbs.). b. For right side knuckles, place the locator block (2) to the right side (3) on the Fixture. The side of the locator block with the angle cut goes downward, toward the Fixture. Install the mounting screws and tighten them to approximately 54 Nm (40 ft. lbs.). 3. Install the knuckle in the Fixture as shown, guiding the steering arm (1) to rest on the locator block (3) and the brake caliper mounting bosses on the two Fixture pins (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 6994 4. Place the Fixture (3) with knuckle in an arbor press. 5. Position Remover/Installer, Special Tool 9712-2 (2), in the small end of the hub. Lower the arbor press ram (1) and remove the hub from the wheel bearing and knuckle. The bearing race will normally come out of the wheel bearing with the hub as it is pressed out of the bearing. 6. Remove the knuckle from the Fixture and turn it over. 7. Remove the snap ring (2) from the knuckle using an appropriate pair of snap ring pliers (1). 8. Place the knuckle back in the Fixture (3) in the arbor press ram. 9. Place Installer (2), Special Tool MD-998334, on the outer race of the wheel bearing. Lower the arbor press ram (1) and remove the wheel bearing from the knuckle. 10. Remove the knuckle and tools from arbor press. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 6995 11. If the bearing race is still pressed onto the hub, install the Bearing Splitter (5), Special Tool 1130, between the hub flange and the bearing inner race (4). 12. Place the hub, bearing race and Bearing Splitter in an arbor press. The press support blocks must not obstruct the wheel hub while it is being pressed out of the bearing race. 13. Place Remover/Installer (2), Special Tool 9712-2, in the end of the hub (3). Lower the arbor press ram (1) and remove the hub from the bearing race. NOTE: For installation, refer to Front Suspension Hub Bearing Installation. Installation INSTALLATION CAUTION: When installing the wheel bearing (1) in the knuckle (2) it is important to place the side of bearing with the wheel speed sensor magnetic encoder ring (dark band) (3) in the knuckle first. Otherwise, the wheel speed sensor will not operate correctly. 1. Wipe the bearing bore of the knuckle clean of any grease or dirt with a clean, dry shop towel. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 6996 2. Place the knuckle in an arbor press supporting the knuckle from underneath using Cup (4), Special Tool 6310-1. 3. Place the NEW wheel bearing (5) magnetic encoder ring side down (see above Caution) into the bore of the knuckle. Be sure the wheel bearing is placed squarely into the bore. 4. Place Receiver (3), Special Tool 8498, larger inside diameter end down over the outer race of the wheel bearing. 5. Place Disc (2), Special Tool 6310-2, into top of Receiver 8498. Lower the arbor press ram (1) and press the wheel bearing into the knuckle until it is bottomed in the bore of the knuckle. 6. Remove the knuckle and tools from the arbor press. 7. Install a NEW snap ring (2) in the knuckle using an appropriate pair of snap ring pliers (1). Make sure the snap ring is fully seated. 8. Place the knuckle in an arbor press. Support the knuckle from underneath using Remover/Installer (3), Special Tool MB-990799, smaller end up against the wheel bearing inner race. 9. Place the hub (4) in the wheel bearing making sure it is square with the bearing inner race. 10. Position Remover/Installer, Special Tool 9712-2 (2), in the end of the hub. Lower the arbor press ram (1) and press the hub into the wheel bearing Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 6997 until it bottoms. 11. Remove the knuckle and tools from the press. 12. Verify the hub turns smoothly without rubbing or binding. 13. Install the knuckle on the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 6998 Wheel Bearing: Service and Repair Rear Suspension All-Wheel-Drive ALL-WHEEL-DRIVE NOTE: Before proceeding, refer to REAR SUSPENSION WARNING. 1. Raise and support the vehicle. 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). 3. Remove the cotter pin (2) from the hub nut (3) on the end of the axle half shaft. 4. While a helper applies the brakes to keep the hub (1) from rotating, remove the hub nut (3) and washer (4) from the axle half shaft. 5. Tap the end of the half shaft inward, loosening it from the hub and bearing. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 6999 6. Remove the disc brake caliper (2) lower guide pin bolt (1). CAUTION: When moving rear brake caliper upward, use extreme care not to damage or overextend the flex hose. Damage may occur. 7. Rotate the caliper upward hinging off the upper guide pin bolt. Rotate the caliper upward just enough to allow brake rotor removal. Hang the caliper assembly in this position using wire or a bungee cord. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 7000 8. Remove any clips (2) retaining the brake rotor (3) to the wheel mounting studs. 9. Slide the brake rotor (3) off the hub and bearing (1). 10. Unclip the wheel speed sensor head (1) from the retainer on the rear of the hub and bearing (2). 11. Remove the four bolts (1) securing the hub and bearing (2) to the trailing link. 12. Remove the hub and bearing. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 7001 Front-Wheel-Drive FRONT-WHEEL-DRIVE NOTE: Before proceeding, refer to REAR SUSPENSION WARNING. 1. Raise and support the vehicle. 2. Remove the wheel mounting nuts (3), then the rear tire and wheel assembly. 3. Remove the disc brake caliper (2) lower guide pin bolt (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 7002 CAUTION: When moving rear brake caliper upward, use extreme care not to damage or overextend the flex hose. Damage may occur. 4. Rotate the caliper upward hinging off the upper guide pin bolt. Rotate the caliper upward just enough to allow brake rotor removal. Hang the caliper assembly in this position using wire or a bungee cord. 5. Remove any clips (2) retaining the brake rotor (3) to the wheel mounting studs. 6. Slide the brake rotor (3) off the hub and bearing (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 7003 7. Remove the screw (1) fastening the wheel speed sensor head (3) in the rear of the hub and bearing (2). 8. Remove the four bolts (1) securing the hub and bearing (2) to the trailing link. 9. Remove the hub and bearing. All-Wheel-Drive ALL-WHEEL-DRIVE Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 7004 1. Slide the hub and bearing over the axle half shaft and position it on the brake support plate and trailing link. 2. Install the four bolts (1) securing the hub and bearing (2) to the trailing link. Tighten the bolts to 105 Nm (77 ft. lbs.). 3. Clip the wheel speed sensor head (1) (flat side to bearing rear) into the retainer on the rear of the hub and bearing (2). 4. Slide the brake rotor (3) over the parking brake shoes and onto the hub and bearing (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 7005 5. Rotate the disc brake caliper downward over the brake rotor and lower part of caliper adapter. 6. Install the disc brake caliper (2) lower guide pin bolt (1). Tighten the guide pin bolt to 60 Nm (44 ft. lbs.). 7. Clean all foreign matter from the threads of the half shaft outer C/V joint. 8. Install the washer (4) and hub nut (3) on the end of the half shaft and snug it. 9. While a helper applies the brakes to keep the hub (1) from rotating, tighten the hub nut (3) to 245 Nm (181 ft. lbs.). 10. Insert the cotter pin (2) through the notches in the nut and the hole in half shaft. If the notches in the nut do not line up with the hole in the half shaft, continue to tighten the nut until they do. Do not loosen the nut. 11. Wrap the cotter pin (2) ends tightly around the lock nut. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 7006 12. Install tire and wheel assembly (1). Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 13. Lower the vehicle. 14. Pump the brake pedal several times to ensure the vehicle has a firm brake pedal before moving it. Front-Wheel-Drive FRONT-WHEEL-DRIVE NOTE: If equipped, make sure the wheel speed sensor mount on the rear of the hub and bearing is directed toward the front of the vehicle. 1. Position the hub and bearing on the brake support plate and trailing link. 2. Install the four bolts (1) securing the hub and bearing (2) to the trailing link. Tighten the bolts to 105 Nm (77 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 7007 3. If equipped, install the wheel speed sensor head (3) into the rear of the hub and bearing (2). 4. Install the wheel speed sensor head mounting screw (1). Tighten the screw to 10 Nm (89 in. lbs.). 5. Slide the brake rotor (3) over the parking brake shoes and onto the hub and bearing (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 7008 6. Rotate the disc brake caliper downward over the brake rotor and lower part of caliper adapter. 7. Install the disc brake caliper (2) lower guide pin bolt (1). Tighten the guide pin bolt to 60 Nm (44 ft. lbs.). 8. Install tire and wheel assembly (1). Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 9. Lower the vehicle. 10. Pump the brake pedal several times to ensure the vehicle has a firm brake pedal before moving it. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Hub Nut Tightening Torque ................................................................................................................. .............................................................. 245 Nm (181 ft. lbs.) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front Tire Pressure Monitor Receiver / Transponder: Locations Transponder-Tire Pressure-Left Front Component ID: 361 Component : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Connector: Name : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Color : YELLOW # of pins : 6 Qualifier : (TIRE PRESSURE MONITOR) Pin Description Circuit 1 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 GROUND Z904 20BK/OR 4 GROUND Z904 20BK/OR 5-6-- Component Location - 13 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 7019 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 7020 Tire Pressure Monitor Receiver / Transponder: Locations Transponder-Tire Pressure-Left Rear Component ID: 362 Component : TRANSPONDER-TIRE PRESSURE-LEFT REAR Connector: Name : TRANSPONDER-TIRE PRESSURE-LEFT REAR Color : BLACK # of pins : 6 Qualifier : (TIRE PRESSURE MONITOR) Pin Description Circuit 1 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 GROUND Z904 20BK/OR 4-5-6-- Component Location - 58 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 7021 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 7022 Tire Pressure Monitor Receiver / Transponder: Locations Transponder-Tire Pressure-Right Rear Component ID: 363 Component : TRANSPONDER-TIRE PRESSURE-RIGHT REAR Connector: Name : TRANSPONDER-TIRE PRESSURE-RIGHT REAR Color : BLACK # of pins : 6 Qualifier : (TIRE PRESSURE MONITOR) Pin Description Circuit 1 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 GROUND Z965 20BK/GY 4-5-6 GROUND Z965 20BK/GY Component Location - 59 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 7023 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front Tire Pressure Monitor Receiver / Transponder: Diagrams Transponder-Tire Pressure-Left Front Component ID: 361 Component : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Connector: Name : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Color : YELLOW # of pins : 6 Qualifier : (TIRE PRESSURE MONITOR) Pin Description Circuit 1 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 GROUND Z904 20BK/OR 4 GROUND Z904 20BK/OR 5-6-- Component Location - 13 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 7026 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 7027 Tire Pressure Monitor Receiver / Transponder: Diagrams Transponder-Tire Pressure-Left Rear Component ID: 362 Component : TRANSPONDER-TIRE PRESSURE-LEFT REAR Connector: Name : TRANSPONDER-TIRE PRESSURE-LEFT REAR Color : BLACK # of pins : 6 Qualifier : (TIRE PRESSURE MONITOR) Pin Description Circuit 1 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 GROUND Z904 20BK/OR 4-5-6-- Component Location - 58 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 7028 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 7029 Tire Pressure Monitor Receiver / Transponder: Diagrams Transponder-Tire Pressure-Right Rear Component ID: 363 Component : TRANSPONDER-TIRE PRESSURE-RIGHT REAR Connector: Name : TRANSPONDER-TIRE PRESSURE-RIGHT REAR Color : BLACK # of pins : 6 Qualifier : (TIRE PRESSURE MONITOR) Pin Description Circuit 1 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 GROUND Z965 20BK/GY 4-5-6 GROUND Z965 20BK/GY Component Location - 59 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 7030 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Description Tire Pressure Monitor Receiver / Transponder: Description and Operation Description DESCRIPTION A transponder, sometimes referred to as a trigger module, is located in three of the four wheel wells (behind the wheelhouse splash shields) of a vehicle equipped with Premium TPM. These transponders are used to provide the Wireless Control Module (WCM), commonly referred to as the Sentry Key Remote Entry Module (SKREEM), with the location of the tire pressure sensors on the vehicle. A fourth transponder is not necessary in the remaining wheel well due to the process-of-elimination theory. Once the system knows the location of the first three sensors it assumes the location of the fourth tire pressure sensor. On this vehicle, there is a transponder located in the left front, left rear, and right rear wheelhouse. There is not a transponder located in the right front wheelhouse. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Description > Page 7033 Tire Pressure Monitor Receiver / Transponder: Description and Operation Operation OPERATION On vehicles equipped with the premium TPM system, the Wireless Control Module (WCM), commonly referred to as the Sentry Key Remote Entry Module (SKREEM), uses transponders (trigger modules) located in three of the four wheel wells on the vehicle to provide it with the location of the tire pressure sensors on the vehicle. Like the base system, the WCM receives RF signals from all four rotating wheel speed sensors. When the WCM needs to know which sensor is located at a particular location on the vehicle, it directs the transponder at that location to send out a low frequency signal to excite the nearby sensor. The WCM then receives that excited signal and knows where that sensor is located. This auto-locating process only happens in the first 10 minutes of any WCM cycle while traveling at speeds above 20 mph (32 km/h). (The auto-locating process will start again only if the vehicle has been shut off for approximately 20 minutes or longer). Once the WCM has performed this to the three locations that have transponders, it uses the process-of-elimination theory to know that the fourth sensor ID signal is coming from. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Removal Tire Pressure Monitor Receiver / Transponder: Service and Repair Removal Front FRONT 1. Remove the wheelhouse splash shield at the transponder requiring service. 2. Disconnect the wiring harness connector (2) at the transponder (1). 3. Remove the mounting nuts (3), then remove the transponder (1). Rear REAR 1. Remove the wheelhouse splash shield at the transponder requiring service. 2. Disconnect the wiring harness connector (3) at the transponder (1). 3. Remove the mounting nuts (2), then remove the transponder (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Removal > Page 7036 Tire Pressure Monitor Receiver / Transponder: Service and Repair Installation Front FRONT 1. Position the transponder (1) and install the mounting nuts (3). 2. Connect the wiring harness connector (2) to the transponder (1). 3. Install the wheelhouse splash shield and all components removed to access it. 4. Perform the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests Rear REAR 1. Position the transponder (1) and install the mounting nuts (2). 2. Connect the wiring harness connector (3) to the transponder (1). 3. Install the rear wheelhouse splash shield and all components removed to access it. 4. Perform the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions Tire Pressure Sensor: Service Precautions CAUTION CAUTION: The use of tire sealants is strictly prohibited for vehicles equipped with the Tire Pressure Monitoring system. Tire sealants can clog tire pressure sensors. CAUTION: Any time a sensor is to be installed in a wheel, it is necessary to install a new sensor-to-wheel seal, metal washer and valve stem nut, to ensure air tight sealing. CAUTION: Tire pressure sensor valve stem caps and cores are specially designed for the sensors. Due to risk of corrosion, do not use a standard valve stem cap or core in a tire pressure sensor in place of the original equipment style sensor cap and core. CAUTION: When installing the valve core, be sure to tighten the core to specifications. Overtightening by a little as three or four inch pounds can damage the sensor. CAUTION: Do not attempt to install a tire pressure sensor in an aftermarket wheel. Use tire pressure sensors in original style factory wheels only. If aftermarket wheels are installed, and therefore do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. NOTE: TPM thresholds have been established for the original tire size equipped on the vehicle. Use original size tires only to maintain system accuracy. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Description Tire Pressure Sensor: Description and Operation Description DESCRIPTION On vehicles equipped with Tire Pressure Monitoring (TPM), one tire pressure sensor (6) is mounted to each wheel (5) in place of the traditional tire valve stem. Each sensor has an internal battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the sensor must be replaced. The TPM system operates on a 315 MHz radio frequency. The 315 MHz sensors can be easily identified by a white outline oval (black center) insignia (3) on the sensor body. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Description > Page 7043 The Export TPM system operates on a 433 MHz radio frequency. The 433 MHz sensors can be easily identified by either a solid white oval insignia (3) on the body or... ... a solid white oval insignia (3) with 433 printed in the center. The sensors are identical except for the oval insignia. The 433 MHz sensors can either have a black or grey sensor body. CAUTION: Although 315 MHz and 433 MHz sensors are identical in size and shape, they are not interchangeable. Always make sure the correct sensor is being used. NOTE: Sensors may be identified by valve stem cap color. From the factory, 315 MHz sensors have a gray valve stem cap while 433 MHz sensors have a black valve stem cap. Otherwise, once mounted inside a tire and wheel assembly you are not able to visually tell the difference between a 315 MHz and 433 MHz sensor. At that point, the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool may be used to identify the sensor frequency or the tire can be dismounted allowing visual inspection of the sensor body. The TPM sensors are designed for original style factory wheels. It is not recommended to install a tire pressure sensor in an aftermarket wheel (This could cause sealing and system performance issues). Do not attempt to install a tire pressure sensor in an aftermarket wheel. If aftermarket wheels are installed and do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Description > Page 7044 The serviceable components of the tire pressure sensor are: - Sensor-To-Wheel Seal (2) and Metal Washer (1) - Valve Stem Cap (4) - Valve Stem Core - Valve Stem Nut (with pressed-in washer) (3) NOTE: Any time a sensor is installed on a wheel, a new Sensor-To-Wheel Seal (2), Metal Washer (1) and Valve Stem Nut (3) must be installed to ensure air tight sealing. A service kit is available. The valve stem caps and cores are specifically designed for the tire pressure monitoring sensors. Although similar to standard valve stem caps and cores, they are different. The valve stem cap has a special seal inside to keep moisture and corrosion out. The valve stem core has a special nickel coating to protect from corrosion. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Description > Page 7045 Tire Pressure Sensor: Description and Operation Operation OPERATION The battery operated tire pressure sensor is both a transmitter and a receiver. The TPM sensor can be forced to transmit by using a special tool such as a TPM-RKE Analyzer, or from a transponder. The TPM-RKE Analyzer has the ability to change the sensor's operating mode to PARK MODE and to help diagnose a faulty TPM sensor. Using a TPM-RKE Analyzer can take up to a minute to force a transmission from a sensor. The TPM sensor can be in one of the following operating modes: - SLEEP MODE - This is the operating mode of a new TPM sensor. If placed on the vehicle as a road tire, the sensor will transmit once every 20 seconds when the vehicle is driven at speeds over 15 mph (24 km/h). Driving the vehicle continuously at this speed for more then 4 minutes will change the sensor state to DRIVE MODE. Stopping the vehicle for 20 minutes will change the sensor state to PARK MODE. If the vehicle is not moving, the sensor will only transmit on a pressure change greater then 1 psi (6.9 kPa). - PARK MODE - This is the correct operating mode when the vehicle is not moving. The sensor will transmit once every 13 hours to update the WCM, or will transmit on a 1 psi (6.9 kPa) delta change. The sensors will internally take a measurement of the tire pressure every minute to determine a change in tire pressure. - 30 BLOCK MODE - If the vehicle has been stopped for more then 20 minutes, or if the sensor's operating mode was forced to PARK MODE using a TPM-RKE Analyzer, the sensor's operating mode will transition from PARK MODE to 30 BLOCK MODE once the vehicle is driven over 15 mph. In this mode, the sensor will transmit once every 15 seconds when the vehicle is driven at speeds over 15 mph (24 km/h) for the first 30 transmissions. After about 8 minutes of continuous driving above 15 mph (24 km/h), the sensor's mode will change to DRIVE MODE. - DRIVE MODE - In this mode, the sensor will transmit once every minute when the vehicle is driven at speeds over 15 mph (24 km/h). At any time the vehicle speed drops below 15 mph, the sensor will not transmit. The sensor mode will still be in drive mode when the sensor reaches speeds over 15 mph (24 km/h), unless the vehicle has been stationary for more then 20 minutes. Each sensor's (transmitter) broadcast is uniquely coded so that the wireless control module (WCM) can monitor the state of each of the sensors on the four rotating road wheels. The WCM can automatically learn and store the sensor's ID while driving "within 10 minutes continuously above 15 mph (24 Km/h)" after a sensor has been replaced. The vehicle must be stationary for more then 20 minutes in order to initiate the learning sequence. The WCM can also learn the sensor's ID using the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool following the procedure listed in the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Removal Tire Pressure Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Remove wheel mounting nuts (3), then tire and wheel assembly (1). CAUTION: The cap used on this valve stem contains an O-ring seal to prevent contamination and moisture from entering the valve stem. Retain this valve stem cap for reuse. Do not substitute a regular valve stem cap in its place. CAUTION: The valve stem used on this vehicle is made of aluminum and the core is nickel plated brass. The original valve stem core must be reinstalled and not substituted with a valve stem core made of a different material. This is required to prevent corrosion in the valve stem caused by the different metals. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Removal > Page 7048 3. Dismount tire from wheel following tire changer manufacturers instructions while paying special attention to the following to avoid damaging the pressure sensor: a. When breaking the tire bead loose from the wheel rim, avoid using the Bead Breaker in the area of the sensor. That includes both front and rear beads of the tire. b. When preparing to dismount the tire from the wheel, carefully insert the mounting/dismounting tool at the valve stem ± 10°, then proceed to dismount the tire from the wheel. Use this process on both the upper and lower tire beads. 4. Remove sensor nut (3) retaining sensor to wheel. While removing nut, hold pressure against rear of metal valve stem to keep valve stem from pushing rearward, damaging antenna strap. 5. Remove sensor (1) from wheel (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Removal > Page 7049 Tire Pressure Sensor: Service and Repair Installation INSTALLATION NOTE: Before reinstalling an existing tire pressure sensor, replace seal (2) and metal washer (1) at base of sensor valve stem (6) to ensure proper sealing. 1. Wipe area clean around sensor/valve stem mounting hole in wheel (5). Make sure surface of wheel is not damaged. CAUTION: To avoid damaging sensor antenna strap (1), hold pressure against rear of metal valve stem (2) while sensor is inserted through wheel mounting hole and nut is installed. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Removal > Page 7050 2. Insert sensor (1) through wheel (2) as shown keeping pressure against rear of metal valve stem (See Arrow). Potted side of sensor is to be positioned toward wheel. Do not attempt to mount sensor otherwise, damage may occur. 3. Install sensor nut (with pressed-in washer) (3) by hand. NOTE: Before tightening sensor nut, push downward on sensor housing (2) in an attempt to make it flush with interior contour of wheel (1). 4. While holding sensor in position, tighten sensor nut to 8 Nm (71 in. lbs.). CAUTION: Over-torquing the sensor nut by as little as 12 Nm (106 in. lbs.) may result in sensor separation from the valve stem. Under this condition, the sensor may still function. However, the condition should be corrected immediately. 5. Mount tire on wheel following tire changer manufacturers instructions, paying special attention to the following to avoid damaging tire pressure sensor: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Removal > Page 7051 a. Rotating Wheel Tire Changers - Once the wheel is mounted to the changer, position the sensor valve stem (2) approximately 210° from the head of the changer (located at 1) in a clockwise direction before rotating the wheel (also in a clockwise direction) to mount the tire. Use this procedure on both the upper and lower tire beads. b. Rotating Tool Tire Changers - Position the wheel on the changer so that the sensor valve stem (1) is located approximately 210° clockwise from the installation end of the mounting/dismounting tool (2) once the tool is mounted for tire installation. Make sure the sensor is clear of the lower bead breaker area (3) to avoid damaging the sensor when the breaker rises. Rotate the tool (2) in a counterclockwise direction to mount the tire. Use this procedure on both the upper and lower tire beads. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Removal > Page 7052 6. Adjust air pressure to that listed on Tire Inflation Pressure Label (Placard) provided with vehicle (applied to driver's side B-pillar). Make sure original style and color valve stem cap is securely installed to keep moisture out of sensor. 7. Install tire and wheel assembly (1) on vehicle. Tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 8. Lower vehicle. 9. Perform one of the following to make the system learn the new sensor ID. a. Use the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool to program the WCM/SKREEM with the tire pressure sensor ID. This is part of the TPM Diagnostic Verification Test. b. Once the vehicle has remained stationary for more than 20 minutes, drive vehicle for a minimum of 10 minutes while maintaining a continuous speed above 15 mph (24 km/h). During this time, the system will learn the new sensor ID. This is part of the TPM Diagnostic Verification Test. NOTE: If a sensor cannot be trained, refer to appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front Tire Pressure Monitor Receiver / Transponder: Locations Transponder-Tire Pressure-Left Front Component ID: 361 Component : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Connector: Name : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Color : YELLOW # of pins : 6 Qualifier : (TIRE PRESSURE MONITOR) Pin Description Circuit 1 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 GROUND Z904 20BK/OR 4 GROUND Z904 20BK/OR 5-6-- Component Location - 13 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 7058 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 7059 Tire Pressure Monitor Receiver / Transponder: Locations Transponder-Tire Pressure-Left Rear Component ID: 362 Component : TRANSPONDER-TIRE PRESSURE-LEFT REAR Connector: Name : TRANSPONDER-TIRE PRESSURE-LEFT REAR Color : BLACK # of pins : 6 Qualifier : (TIRE PRESSURE MONITOR) Pin Description Circuit 1 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 GROUND Z904 20BK/OR 4-5-6-- Component Location - 58 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 7060 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 7061 Tire Pressure Monitor Receiver / Transponder: Locations Transponder-Tire Pressure-Right Rear Component ID: 363 Component : TRANSPONDER-TIRE PRESSURE-RIGHT REAR Connector: Name : TRANSPONDER-TIRE PRESSURE-RIGHT REAR Color : BLACK # of pins : 6 Qualifier : (TIRE PRESSURE MONITOR) Pin Description Circuit 1 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 GROUND Z965 20BK/GY 4-5-6 GROUND Z965 20BK/GY Component Location - 59 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 7062 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front Tire Pressure Monitor Receiver / Transponder: Diagrams Transponder-Tire Pressure-Left Front Component ID: 361 Component : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Connector: Name : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Color : YELLOW # of pins : 6 Qualifier : (TIRE PRESSURE MONITOR) Pin Description Circuit 1 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 GROUND Z904 20BK/OR 4 GROUND Z904 20BK/OR 5-6-- Component Location - 13 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 7065 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 7066 Tire Pressure Monitor Receiver / Transponder: Diagrams Transponder-Tire Pressure-Left Rear Component ID: 362 Component : TRANSPONDER-TIRE PRESSURE-LEFT REAR Connector: Name : TRANSPONDER-TIRE PRESSURE-LEFT REAR Color : BLACK # of pins : 6 Qualifier : (TIRE PRESSURE MONITOR) Pin Description Circuit 1 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 GROUND Z904 20BK/OR 4-5-6-- Component Location - 58 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 7067 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 7068 Tire Pressure Monitor Receiver / Transponder: Diagrams Transponder-Tire Pressure-Right Rear Component ID: 363 Component : TRANSPONDER-TIRE PRESSURE-RIGHT REAR Connector: Name : TRANSPONDER-TIRE PRESSURE-RIGHT REAR Color : BLACK # of pins : 6 Qualifier : (TIRE PRESSURE MONITOR) Pin Description Circuit 1 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 GROUND Z965 20BK/GY 4-5-6 GROUND Z965 20BK/GY Component Location - 59 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 7069 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Description Tire Pressure Monitor Receiver / Transponder: Description and Operation Description DESCRIPTION A transponder, sometimes referred to as a trigger module, is located in three of the four wheel wells (behind the wheelhouse splash shields) of a vehicle equipped with Premium TPM. These transponders are used to provide the Wireless Control Module (WCM), commonly referred to as the Sentry Key Remote Entry Module (SKREEM), with the location of the tire pressure sensors on the vehicle. A fourth transponder is not necessary in the remaining wheel well due to the process-of-elimination theory. Once the system knows the location of the first three sensors it assumes the location of the fourth tire pressure sensor. On this vehicle, there is a transponder located in the left front, left rear, and right rear wheelhouse. There is not a transponder located in the right front wheelhouse. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Description > Page 7072 Tire Pressure Monitor Receiver / Transponder: Description and Operation Operation OPERATION On vehicles equipped with the premium TPM system, the Wireless Control Module (WCM), commonly referred to as the Sentry Key Remote Entry Module (SKREEM), uses transponders (trigger modules) located in three of the four wheel wells on the vehicle to provide it with the location of the tire pressure sensors on the vehicle. Like the base system, the WCM receives RF signals from all four rotating wheel speed sensors. When the WCM needs to know which sensor is located at a particular location on the vehicle, it directs the transponder at that location to send out a low frequency signal to excite the nearby sensor. The WCM then receives that excited signal and knows where that sensor is located. This auto-locating process only happens in the first 10 minutes of any WCM cycle while traveling at speeds above 20 mph (32 km/h). (The auto-locating process will start again only if the vehicle has been shut off for approximately 20 minutes or longer). Once the WCM has performed this to the three locations that have transponders, it uses the process-of-elimination theory to know that the fourth sensor ID signal is coming from. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Removal Tire Pressure Monitor Receiver / Transponder: Service and Repair Removal Front FRONT 1. Remove the wheelhouse splash shield at the transponder requiring service. 2. Disconnect the wiring harness connector (2) at the transponder (1). 3. Remove the mounting nuts (3), then remove the transponder (1). Rear REAR 1. Remove the wheelhouse splash shield at the transponder requiring service. 2. Disconnect the wiring harness connector (3) at the transponder (1). 3. Remove the mounting nuts (2), then remove the transponder (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Removal > Page 7075 Tire Pressure Monitor Receiver / Transponder: Service and Repair Installation Front FRONT 1. Position the transponder (1) and install the mounting nuts (3). 2. Connect the wiring harness connector (2) to the transponder (1). 3. Install the wheelhouse splash shield and all components removed to access it. 4. Perform the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests Rear REAR 1. Position the transponder (1) and install the mounting nuts (2). 2. Connect the wiring harness connector (3) to the transponder (1). 3. Install the rear wheelhouse splash shield and all components removed to access it. 4. Perform the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service Precautions Tire Pressure Sensor: Service Precautions CAUTION CAUTION: The use of tire sealants is strictly prohibited for vehicles equipped with the Tire Pressure Monitoring system. Tire sealants can clog tire pressure sensors. CAUTION: Any time a sensor is to be installed in a wheel, it is necessary to install a new sensor-to-wheel seal, metal washer and valve stem nut, to ensure air tight sealing. CAUTION: Tire pressure sensor valve stem caps and cores are specially designed for the sensors. Due to risk of corrosion, do not use a standard valve stem cap or core in a tire pressure sensor in place of the original equipment style sensor cap and core. CAUTION: When installing the valve core, be sure to tighten the core to specifications. Overtightening by a little as three or four inch pounds can damage the sensor. CAUTION: Do not attempt to install a tire pressure sensor in an aftermarket wheel. Use tire pressure sensors in original style factory wheels only. If aftermarket wheels are installed, and therefore do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. NOTE: TPM thresholds have been established for the original tire size equipped on the vehicle. Use original size tires only to maintain system accuracy. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Description and Operation > Description Tire Pressure Sensor: Description and Operation Description DESCRIPTION On vehicles equipped with Tire Pressure Monitoring (TPM), one tire pressure sensor (6) is mounted to each wheel (5) in place of the traditional tire valve stem. Each sensor has an internal battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the sensor must be replaced. The TPM system operates on a 315 MHz radio frequency. The 315 MHz sensors can be easily identified by a white outline oval (black center) insignia (3) on the sensor body. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Description and Operation > Description > Page 7081 The Export TPM system operates on a 433 MHz radio frequency. The 433 MHz sensors can be easily identified by either a solid white oval insignia (3) on the body or... ... a solid white oval insignia (3) with 433 printed in the center. The sensors are identical except for the oval insignia. The 433 MHz sensors can either have a black or grey sensor body. CAUTION: Although 315 MHz and 433 MHz sensors are identical in size and shape, they are not interchangeable. Always make sure the correct sensor is being used. NOTE: Sensors may be identified by valve stem cap color. From the factory, 315 MHz sensors have a gray valve stem cap while 433 MHz sensors have a black valve stem cap. Otherwise, once mounted inside a tire and wheel assembly you are not able to visually tell the difference between a 315 MHz and 433 MHz sensor. At that point, the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool may be used to identify the sensor frequency or the tire can be dismounted allowing visual inspection of the sensor body. The TPM sensors are designed for original style factory wheels. It is not recommended to install a tire pressure sensor in an aftermarket wheel (This could cause sealing and system performance issues). Do not attempt to install a tire pressure sensor in an aftermarket wheel. If aftermarket wheels are installed and do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Description and Operation > Description > Page 7082 The serviceable components of the tire pressure sensor are: - Sensor-To-Wheel Seal (2) and Metal Washer (1) - Valve Stem Cap (4) - Valve Stem Core - Valve Stem Nut (with pressed-in washer) (3) NOTE: Any time a sensor is installed on a wheel, a new Sensor-To-Wheel Seal (2), Metal Washer (1) and Valve Stem Nut (3) must be installed to ensure air tight sealing. A service kit is available. The valve stem caps and cores are specifically designed for the tire pressure monitoring sensors. Although similar to standard valve stem caps and cores, they are different. The valve stem cap has a special seal inside to keep moisture and corrosion out. The valve stem core has a special nickel coating to protect from corrosion. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Description and Operation > Description > Page 7083 Tire Pressure Sensor: Description and Operation Operation OPERATION The battery operated tire pressure sensor is both a transmitter and a receiver. The TPM sensor can be forced to transmit by using a special tool such as a TPM-RKE Analyzer, or from a transponder. The TPM-RKE Analyzer has the ability to change the sensor's operating mode to PARK MODE and to help diagnose a faulty TPM sensor. Using a TPM-RKE Analyzer can take up to a minute to force a transmission from a sensor. The TPM sensor can be in one of the following operating modes: - SLEEP MODE - This is the operating mode of a new TPM sensor. If placed on the vehicle as a road tire, the sensor will transmit once every 20 seconds when the vehicle is driven at speeds over 15 mph (24 km/h). Driving the vehicle continuously at this speed for more then 4 minutes will change the sensor state to DRIVE MODE. Stopping the vehicle for 20 minutes will change the sensor state to PARK MODE. If the vehicle is not moving, the sensor will only transmit on a pressure change greater then 1 psi (6.9 kPa). - PARK MODE - This is the correct operating mode when the vehicle is not moving. The sensor will transmit once every 13 hours to update the WCM, or will transmit on a 1 psi (6.9 kPa) delta change. The sensors will internally take a measurement of the tire pressure every minute to determine a change in tire pressure. - 30 BLOCK MODE - If the vehicle has been stopped for more then 20 minutes, or if the sensor's operating mode was forced to PARK MODE using a TPM-RKE Analyzer, the sensor's operating mode will transition from PARK MODE to 30 BLOCK MODE once the vehicle is driven over 15 mph. In this mode, the sensor will transmit once every 15 seconds when the vehicle is driven at speeds over 15 mph (24 km/h) for the first 30 transmissions. After about 8 minutes of continuous driving above 15 mph (24 km/h), the sensor's mode will change to DRIVE MODE. - DRIVE MODE - In this mode, the sensor will transmit once every minute when the vehicle is driven at speeds over 15 mph (24 km/h). At any time the vehicle speed drops below 15 mph, the sensor will not transmit. The sensor mode will still be in drive mode when the sensor reaches speeds over 15 mph (24 km/h), unless the vehicle has been stationary for more then 20 minutes. Each sensor's (transmitter) broadcast is uniquely coded so that the wireless control module (WCM) can monitor the state of each of the sensors on the four rotating road wheels. The WCM can automatically learn and store the sensor's ID while driving "within 10 minutes continuously above 15 mph (24 Km/h)" after a sensor has been replaced. The vehicle must be stationary for more then 20 minutes in order to initiate the learning sequence. The WCM can also learn the sensor's ID using the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool following the procedure listed in the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Removal Tire Pressure Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Remove wheel mounting nuts (3), then tire and wheel assembly (1). CAUTION: The cap used on this valve stem contains an O-ring seal to prevent contamination and moisture from entering the valve stem. Retain this valve stem cap for reuse. Do not substitute a regular valve stem cap in its place. CAUTION: The valve stem used on this vehicle is made of aluminum and the core is nickel plated brass. The original valve stem core must be reinstalled and not substituted with a valve stem core made of a different material. This is required to prevent corrosion in the valve stem caused by the different metals. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Removal > Page 7086 3. Dismount tire from wheel following tire changer manufacturers instructions while paying special attention to the following to avoid damaging the pressure sensor: a. When breaking the tire bead loose from the wheel rim, avoid using the Bead Breaker in the area of the sensor. That includes both front and rear beads of the tire. b. When preparing to dismount the tire from the wheel, carefully insert the mounting/dismounting tool at the valve stem ± 10°, then proceed to dismount the tire from the wheel. Use this process on both the upper and lower tire beads. 4. Remove sensor nut (3) retaining sensor to wheel. While removing nut, hold pressure against rear of metal valve stem to keep valve stem from pushing rearward, damaging antenna strap. 5. Remove sensor (1) from wheel (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Removal > Page 7087 Tire Pressure Sensor: Service and Repair Installation INSTALLATION NOTE: Before reinstalling an existing tire pressure sensor, replace seal (2) and metal washer (1) at base of sensor valve stem (6) to ensure proper sealing. 1. Wipe area clean around sensor/valve stem mounting hole in wheel (5). Make sure surface of wheel is not damaged. CAUTION: To avoid damaging sensor antenna strap (1), hold pressure against rear of metal valve stem (2) while sensor is inserted through wheel mounting hole and nut is installed. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Removal > Page 7088 2. Insert sensor (1) through wheel (2) as shown keeping pressure against rear of metal valve stem (See Arrow). Potted side of sensor is to be positioned toward wheel. Do not attempt to mount sensor otherwise, damage may occur. 3. Install sensor nut (with pressed-in washer) (3) by hand. NOTE: Before tightening sensor nut, push downward on sensor housing (2) in an attempt to make it flush with interior contour of wheel (1). 4. While holding sensor in position, tighten sensor nut to 8 Nm (71 in. lbs.). CAUTION: Over-torquing the sensor nut by as little as 12 Nm (106 in. lbs.) may result in sensor separation from the valve stem. Under this condition, the sensor may still function. However, the condition should be corrected immediately. 5. Mount tire on wheel following tire changer manufacturers instructions, paying special attention to the following to avoid damaging tire pressure sensor: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Removal > Page 7089 a. Rotating Wheel Tire Changers - Once the wheel is mounted to the changer, position the sensor valve stem (2) approximately 210° from the head of the changer (located at 1) in a clockwise direction before rotating the wheel (also in a clockwise direction) to mount the tire. Use this procedure on both the upper and lower tire beads. b. Rotating Tool Tire Changers - Position the wheel on the changer so that the sensor valve stem (1) is located approximately 210° clockwise from the installation end of the mounting/dismounting tool (2) once the tool is mounted for tire installation. Make sure the sensor is clear of the lower bead breaker area (3) to avoid damaging the sensor when the breaker rises. Rotate the tool (2) in a counterclockwise direction to mount the tire. Use this procedure on both the upper and lower tire beads. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Removal > Page 7090 6. Adjust air pressure to that listed on Tire Inflation Pressure Label (Placard) provided with vehicle (applied to driver's side B-pillar). Make sure original style and color valve stem cap is securely installed to keep moisture out of sensor. 7. Install tire and wheel assembly (1) on vehicle. Tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 8. Lower vehicle. 9. Perform one of the following to make the system learn the new sensor ID. a. Use the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool to program the WCM/SKREEM with the tire pressure sensor ID. This is part of the TPM Diagnostic Verification Test. b. Once the vehicle has remained stationary for more than 20 minutes, drive vehicle for a minimum of 10 minutes while maintaining a continuous speed above 15 mph (24 km/h). During this time, the system will learn the new sensor ID. This is part of the TPM Diagnostic Verification Test. NOTE: If a sensor cannot be trained, refer to appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Technical Service Bulletins > Tire Monitor System - Dashes Displayed Using Spare Tire Spare Tire: Technical Service Bulletins Tire Monitor System - Dashes Displayed Using Spare Tire NUMBER: 22-001-06 REV. B GROUP: Tires & Wheels DATE: August 12, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 22-001-06 REV. A, DATED JUNE 29, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITIONAL MODELS. SUBJECT: Tire Pressure Monitoring System (1PM) Displays Dashes "--" When The Spare Tire Is Used MODELS: 2007 (PM) Caliber 2007 (MK-49) Compass **2007 (JS) **2007 (KA) Nitro** DISCUSSION: If the TPM system detects a low tire, it will set a low tire DTC (C0077 - Low Tire Pressure), notify the customer by illuminating the TPM telltale, and display the low tire pressure values in the EVIC display. Once the low road tire is replaced by the spare tire and the vehicle is driven above 25 MPH (40 KPH) for more than 10 minutes; the TPM system will set an additional DTC (C151C - Tire Pressure Sensor Missing), notify the customer by displaying "CHECK TPM SYSTEM" for 3 seconds, and replaces the low tire pressure value with dashes If: ^ The original tire with pressure sensor remains inside the vehicle or within a valid Radio Frequency range with the WCM (TPM receiver). And: ^ The pressure changes in the low tire by more than 1 PSI or 13 hours expire from the time the low tire event occurred. Then: ^ The dashes will be replaced by the actual low tire pressure value. This low tire / dash "--" cycle will repeat until the pressure is restored in the original tire. NOTE: The spare tire is not equipped with a tire pressure monitoring (TPM) sensor. Do not replace any TPM sensors for this condition. Correct the low tire condition first and then verify that the C151C - Tire Pressure Sensor Missing and the C0077 - Low Tire Pressure DTC change to a stored code. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Technical Service Bulletins > Tire Monitor System - Dashes Displayed Using Spare Tire > Page 7096 Spare Tire: Technical Service Bulletins Tire Monitor System - Displays Dashes When Using Spare NUMBER: 22-001-06 GROUP: Tires & Wheels DATE: February 8, 2006 SUBJECT: Tire Pressure Monitoring System (1PM) Displays Dashes "--" When The Spare Tire Is Used. MODELS: 2007 (PM) Caliber DISCUSSION: If the TPM system detects a low tire, it will set a low tire DTC (C0077 - Low Tire Pressure), notify the customer by illuminating the TPM telltale, and display the low tire pressure values in the EVIC display. Once the low road tire is replaced by the spare tire and the vehicle is driven above 25 MPH (40 KPH) for more than 10 minutes; the TPM system will set an additional DTC (C151C - Tire Pressure Sensor Missing), notify the customer by displaying "CHECK TPM SYSTEM" for 3 seconds, and replaces the low tire pressure value with dashes If: ^ The original tire with pressure sensor remains inside the vehicle or within a valid Radio Frequency range with the WCM (TPM receiver). And: ^ The pressure changes in the low tire by more than 1 PSI or 13 hours expire from the time the low tire event occurred. Then: ^ The dashes will be replaced by the actual low tire pressure value. This low tire / dash "--" cycle will repeat until the pressure is restored in the original tire. NOTE: The spare tire is not equipped with a tire pressure monitoring (TPM) sensor. Do not replace any TPM sensors for this condition. Correct the low tire condition first and then verify that the C151C - Tire Pressure Sensor Missing and the C0077 - Low Tire Pressure DTC change to a stored code. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Chrome Clad Wheel Balancing Information Wheels: Technical Service Bulletins Wheels/Tires - Chrome Clad Wheel Balancing Information NUMBER: 22-002-09 GROUP: Wheels/Tires DATE: July 29, 2009 SUBJECT: Chrome Clad Wheel Adapters For Proper Balancing OVERVIEW: This bulletin describes the use of proper wheel adapters when mounting Chrome Clad wheels to wheel balancing equipment. MODELS: 2004-2008 (CS) Pacifica 2007 - 2009 (D1) Ram Truck (3500 Pick Up) 2007 - 2010 DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2004 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2009-2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2008 - 2010 (JS27) Sebring Convertible 2007 - 2010 (JS41) Sebring/Avenger 2007-2010 (KA) Nitro 2002-2007 (KJ) Liberty 2002 - 2007 (KJ) Cherokee (International Markets) 2008 - 2010 (KK) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005-2010 (ND) Dakota 2007 - 2001 (PM) Caliber 2001 - 2009 (PT) Chrysler PT Cruiser 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2008 - 2010 (RI) Town & Country/Grand Caravan Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Chrome Clad Wheel Balancing Information > Page 7101 2008 - 2010 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005-2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander NOTE: This information applies to any model equipped with Chrome Clad Wheels. DISCUSSION: Models equipped with Chrome Clad wheels require specific piloting on balance equipment to properly center the wheel and prevent damage to the chrome clad surface. The chrome cladding is not removable or replaceable and has cladding tabs that extend into the wheel bore. Traditional high-taper cones will come into contact with the cladding tabs rather than properly seat on the hub bore chamfer. Many modern aluminum wheel designs cannot be mounted with traditional cones. Direct-Fit Collets should be used to properly mount clad wheels on balance equipment (Fig 1). SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: This kit includes the adapters for all Dodge, Chrysler & Jeep models with clad wheels. Individual adapters for specific wheel sizes can be ordered separately. To order a kit or individual adapters, contact Pentastar Service Equipment @ 1-800-223-5623. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 7102 Wheels: Specifications WHEEL Torque Specifcations Torque Specifications Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 7103 Wheels: Description and Operation WHEEL All vehicles use either steel or cast aluminum drop center wheels. The original equipment wheels are designed for proper operation at all loads up to the specified maximum vehicle capacity. Every wheel has raised sections between the rim flanges (1) and drop well (3) called safety humps (2). In case of air loss, these raised sections help hold the tire in position on the wheel until the vehicle can be brought to a safe stop. When being installed on the wheel, initial inflation of the tire forces the tire bead over these raised sections into place. The wheel studs and nuts are designed for specific wheel applications and must be replaced with equivalent parts. Do not use replacement parts of lesser quality or of a substitute design. All aluminum and steel wheels have wheel stud nuts with an enlarged nose. This enlarged nose is necessary to ensure proper retention of the wheels. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 7104 Wheels: Testing and Inspection WHEEL INSPECTION Inspect wheels for: - Excessive runout - Dents, cracks or irregular bends - Damaged wheel stud (lug) holes - Air Leaks NOTE: Do not attempt to repair a wheel by hammering, heating or welding. If a wheel is damaged, an original equipment replacement wheel should be used. When obtaining replacement wheels, they must be equivalent in load carrying capacity. The diameter, width, offset, pilot hole and bolt circle of the wheel should be the same as the original wheel. WARNING: Failure to use equivalent replacement wheels may adversely affect the safety and handling of the vehicle. WARNING: Replacement with used wheels is not recommended. The service history of the wheel may have included severe treatment or very high mileage. The rim could fail without warning. WARNING: DaimlerChrysler Corporation does not recommend that customers use "reconditioned" wheels (wheels that have been damaged and repaired) because they can result in a sudden catastrophic wheel failure which could cause loss of control and result in injury or death. For clarification: - Cosmetic refinishing for the purpose of repairing a superficial flaw is an acceptable procedure providing it is limited to paint or clear coat only, the wheel is not modified in any way, and there is no exposure to paint curing heat over 200 degrees Fahrenheit. - Damaged wheels are those which have been bent, broken, cracked or sustained some other physical damage which may have compromised the wheel structure. - Repaired indicates that the wheel has been modified through bending, welding, heating, straightening, or material removal to rectify damage. - Re-plating of chrome plated wheels is not an acceptable procedure nor is chrome plating of original equipment painted or polished wheels, as this may alter mechanical properties and affect fatigue life. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 7105 Wheels: Service and Repair WHEEL AND WHEEL TRIM CARE All wheels and wheel trim, especially aluminum and chrome plated, should be cleaned regularly using mild soap and water to maintain their luster and to prevent corrosion. Wash them with the same soap solution recommended for the body of the vehicle. When cleaning extremely dirty wheels, care must be taken in the selection of tire and wheel cleaning chemicals and equipment to prevent damage to the wheels. Mopar(R) Tire & Wheel Cleaner, Mopar(R) Wheel Treatment or Mopar(R) Chrome Cleaner is recommended. Any of the "DO NOT USE" items listed below can damage wheels and wheel trim. DO NOT USE: - Any abrasive cleaner - Any abrasive cleaning pad (such as steel wool) or abrasive brush - Any cleaner that contains an acid which can react with and discolor the chrome surface. Many wheel cleaners contain acids that can harm the wheel surface. - Oven cleaner - A car wash that uses carbide-tipped wheel cleaning brushes or acidic solutions. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Description and Operation > Front Suspension Wheel Bearing: Description and Operation Front Suspension DESCRIPTION The wheel bearing (5) and hub (3) are pressed into the knuckle (1). The wheel bearing is secured in place using a snap ring. One side of the wheel bearing has an integrated magnetic encoder ring for wheel speed sensor usage as equipped. It is important that the wheel speed sensor magnetic encoder ring (dark band) (3) be positioned to the inside of the knuckle or the wheel speed sensor will not operate correctly. The wheel bearing is a Unit 1 type cartridge bearing that requires no maintenance. The wheel bearing can be serviced separately from the hub. The hub supports the driveline halfshaft outer constant velocity (C/V) joint. Each is splined and meshes in the center of the hub. The outer C/V joint is retained to the hub using a nut. The nut is locked to the outer C/V stub shaft using a cotter pin. The hub has five studs pressed into its flange. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Description and Operation > Front Suspension > Page 7110 Wheel Bearing: Description and Operation Rear Suspension DESCRIPTION The rear wheel bearing and wheel mounting hub used on this vehicle are a one-piece sealed unit or hub and bearing assembly. It is permanently lubricated when assembled and is sealed for life. There is no periodic lubrication or maintenance recommended for these units. The hub and bearing (5) is mounted to the trailing link (1). All vehicles have a magnetic encoder integrated into the right rear hub and bearing for speed sense. Vehicles equipped with antilock brakes have a magnetic encoder integrated into both rear hub and bearings. The encoder works with the rear wheel speed sensors to provide wheel speed signal. The sensor mounts by screw to the rear of the front-wheel-drive hub and bearing while the sensor clips to the rear of the all-wheel-drive hub and bearing. The only serviceable components of the hub and bearing are the wheel mounting studs pressed into the hub. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Front Suspension Wheel Bearing: Testing and Inspection Front Suspension WHEEL BEARING AND HUB NOTE: The wheel bearing is designed to last for the life of the vehicle and requires no type of periodic maintenance. The following procedure may be used for diagnosing the condition of the wheel bearing and hub. 1. Remove the wheel and tire assembly, disc brake caliper and brake rotor. 2. Rotate the wheel hub checking for resistance or roughness. Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing. If the bearing exhibits any of these conditions, the hub bearing will require replacement. Do not attempt to disassemble the bearing for repair. If the wheel bearing is disassembled for any reason, it must be replaced. Damaged bearing seals and the resulting excessive grease loss may also require bearing replacement. Moderate grease weeping from the bearing is considered normal and should not require replacement of the wheel bearing. To diagnose a bent hub, measure hub runout. Refer to Brakes and Traction Control/Testing and inspection. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Front Suspension > Page 7113 Wheel Bearing: Testing and Inspection Rear Suspension HUB AND BEARING NOTE: The wheel bearing is designed to last for the life of the vehicle and requires no type of periodic maintenance. The following procedure may be used for diagnosing the condition of the wheel bearing and hub. 1. Remove the wheel and tire assembly, disc brake caliper and brake rotor. 2. Rotate the wheel hub checking for resistance or roughness. Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing. If the bearing exhibits any of these conditions, the hub and bearing will require replacement. Do not attempt to disassemble the bearing for repair. If the wheel bearing is disassembled for any reason, it must be replaced. Damaged bearing seals and the resulting excessive grease loss may also require bearing replacement. Moderate grease seepage from the bearing is considered normal and should not require replacement of the wheel bearing. To diagnose a bent hub, measure hub runout. Refer to Brakes and Traction Control/Testing and Inspection. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension Wheel Bearing: Service and Repair Front Suspension Removal REMOVAL NOTE: The removal and installation of the wheel bearing and hub from the knuckle is only to be done with the knuckle removed from the vehicle. 1. Remove the steering knuckle from the vehicle. 2. Position the locator block (2) for Fixture, Special Tool 9712, as follows: a. For left side knuckles, place the locator block (2) to the left side (4) on the Fixture. The side of the locator block with the angle cut goes downward, toward the Fixture. Install the mounting screws and tighten them to approximately 54 Nm (40 ft. lbs.). b. For right side knuckles, place the locator block (2) to the right side (3) on the Fixture. The side of the locator block with the angle cut goes downward, toward the Fixture. Install the mounting screws and tighten them to approximately 54 Nm (40 ft. lbs.). 3. Install the knuckle in the Fixture as shown, guiding the steering arm (1) to rest on the locator block (3) and the brake caliper mounting bosses on the two Fixture pins (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 7116 4. Place the Fixture (3) with knuckle in an arbor press. 5. Position Remover/Installer, Special Tool 9712-2 (2), in the small end of the hub. Lower the arbor press ram (1) and remove the hub from the wheel bearing and knuckle. The bearing race will normally come out of the wheel bearing with the hub as it is pressed out of the bearing. 6. Remove the knuckle from the Fixture and turn it over. 7. Remove the snap ring (2) from the knuckle using an appropriate pair of snap ring pliers (1). 8. Place the knuckle back in the Fixture (3) in the arbor press ram. 9. Place Installer (2), Special Tool MD-998334, on the outer race of the wheel bearing. Lower the arbor press ram (1) and remove the wheel bearing from the knuckle. 10. Remove the knuckle and tools from arbor press. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 7117 11. If the bearing race is still pressed onto the hub, install the Bearing Splitter (5), Special Tool 1130, between the hub flange and the bearing inner race (4). 12. Place the hub, bearing race and Bearing Splitter in an arbor press. The press support blocks must not obstruct the wheel hub while it is being pressed out of the bearing race. 13. Place Remover/Installer (2), Special Tool 9712-2, in the end of the hub (3). Lower the arbor press ram (1) and remove the hub from the bearing race. NOTE: For installation, refer to Front Suspension Hub Bearing Installation. Installation INSTALLATION CAUTION: When installing the wheel bearing (1) in the knuckle (2) it is important to place the side of bearing with the wheel speed sensor magnetic encoder ring (dark band) (3) in the knuckle first. Otherwise, the wheel speed sensor will not operate correctly. 1. Wipe the bearing bore of the knuckle clean of any grease or dirt with a clean, dry shop towel. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 7118 2. Place the knuckle in an arbor press supporting the knuckle from underneath using Cup (4), Special Tool 6310-1. 3. Place the NEW wheel bearing (5) magnetic encoder ring side down (see above Caution) into the bore of the knuckle. Be sure the wheel bearing is placed squarely into the bore. 4. Place Receiver (3), Special Tool 8498, larger inside diameter end down over the outer race of the wheel bearing. 5. Place Disc (2), Special Tool 6310-2, into top of Receiver 8498. Lower the arbor press ram (1) and press the wheel bearing into the knuckle until it is bottomed in the bore of the knuckle. 6. Remove the knuckle and tools from the arbor press. 7. Install a NEW snap ring (2) in the knuckle using an appropriate pair of snap ring pliers (1). Make sure the snap ring is fully seated. 8. Place the knuckle in an arbor press. Support the knuckle from underneath using Remover/Installer (3), Special Tool MB-990799, smaller end up against the wheel bearing inner race. 9. Place the hub (4) in the wheel bearing making sure it is square with the bearing inner race. 10. Position Remover/Installer, Special Tool 9712-2 (2), in the end of the hub. Lower the arbor press ram (1) and press the hub into the wheel bearing Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 7119 until it bottoms. 11. Remove the knuckle and tools from the press. 12. Verify the hub turns smoothly without rubbing or binding. 13. Install the knuckle on the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 7120 Wheel Bearing: Service and Repair Rear Suspension All-Wheel-Drive ALL-WHEEL-DRIVE NOTE: Before proceeding, refer to REAR SUSPENSION WARNING. 1. Raise and support the vehicle. 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). 3. Remove the cotter pin (2) from the hub nut (3) on the end of the axle half shaft. 4. While a helper applies the brakes to keep the hub (1) from rotating, remove the hub nut (3) and washer (4) from the axle half shaft. 5. Tap the end of the half shaft inward, loosening it from the hub and bearing. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 7121 6. Remove the disc brake caliper (2) lower guide pin bolt (1). CAUTION: When moving rear brake caliper upward, use extreme care not to damage or overextend the flex hose. Damage may occur. 7. Rotate the caliper upward hinging off the upper guide pin bolt. Rotate the caliper upward just enough to allow brake rotor removal. Hang the caliper assembly in this position using wire or a bungee cord. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 7122 8. Remove any clips (2) retaining the brake rotor (3) to the wheel mounting studs. 9. Slide the brake rotor (3) off the hub and bearing (1). 10. Unclip the wheel speed sensor head (1) from the retainer on the rear of the hub and bearing (2). 11. Remove the four bolts (1) securing the hub and bearing (2) to the trailing link. 12. Remove the hub and bearing. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 7123 Front-Wheel-Drive FRONT-WHEEL-DRIVE NOTE: Before proceeding, refer to REAR SUSPENSION WARNING. 1. Raise and support the vehicle. 2. Remove the wheel mounting nuts (3), then the rear tire and wheel assembly. 3. Remove the disc brake caliper (2) lower guide pin bolt (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 7124 CAUTION: When moving rear brake caliper upward, use extreme care not to damage or overextend the flex hose. Damage may occur. 4. Rotate the caliper upward hinging off the upper guide pin bolt. Rotate the caliper upward just enough to allow brake rotor removal. Hang the caliper assembly in this position using wire or a bungee cord. 5. Remove any clips (2) retaining the brake rotor (3) to the wheel mounting studs. 6. Slide the brake rotor (3) off the hub and bearing (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 7125 7. Remove the screw (1) fastening the wheel speed sensor head (3) in the rear of the hub and bearing (2). 8. Remove the four bolts (1) securing the hub and bearing (2) to the trailing link. 9. Remove the hub and bearing. All-Wheel-Drive ALL-WHEEL-DRIVE Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 7126 1. Slide the hub and bearing over the axle half shaft and position it on the brake support plate and trailing link. 2. Install the four bolts (1) securing the hub and bearing (2) to the trailing link. Tighten the bolts to 105 Nm (77 ft. lbs.). 3. Clip the wheel speed sensor head (1) (flat side to bearing rear) into the retainer on the rear of the hub and bearing (2). 4. Slide the brake rotor (3) over the parking brake shoes and onto the hub and bearing (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 7127 5. Rotate the disc brake caliper downward over the brake rotor and lower part of caliper adapter. 6. Install the disc brake caliper (2) lower guide pin bolt (1). Tighten the guide pin bolt to 60 Nm (44 ft. lbs.). 7. Clean all foreign matter from the threads of the half shaft outer C/V joint. 8. Install the washer (4) and hub nut (3) on the end of the half shaft and snug it. 9. While a helper applies the brakes to keep the hub (1) from rotating, tighten the hub nut (3) to 245 Nm (181 ft. lbs.). 10. Insert the cotter pin (2) through the notches in the nut and the hole in half shaft. If the notches in the nut do not line up with the hole in the half shaft, continue to tighten the nut until they do. Do not loosen the nut. 11. Wrap the cotter pin (2) ends tightly around the lock nut. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 7128 12. Install tire and wheel assembly (1). Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 13. Lower the vehicle. 14. Pump the brake pedal several times to ensure the vehicle has a firm brake pedal before moving it. Front-Wheel-Drive FRONT-WHEEL-DRIVE NOTE: If equipped, make sure the wheel speed sensor mount on the rear of the hub and bearing is directed toward the front of the vehicle. 1. Position the hub and bearing on the brake support plate and trailing link. 2. Install the four bolts (1) securing the hub and bearing (2) to the trailing link. Tighten the bolts to 105 Nm (77 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 7129 3. If equipped, install the wheel speed sensor head (3) into the rear of the hub and bearing (2). 4. Install the wheel speed sensor head mounting screw (1). Tighten the screw to 10 Nm (89 in. lbs.). 5. Slide the brake rotor (3) over the parking brake shoes and onto the hub and bearing (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 7130 6. Rotate the disc brake caliper downward over the brake rotor and lower part of caliper adapter. 7. Install the disc brake caliper (2) lower guide pin bolt (1). Tighten the guide pin bolt to 60 Nm (44 ft. lbs.). 8. Install tire and wheel assembly (1). Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 9. Lower the vehicle. 10. Pump the brake pedal several times to ensure the vehicle has a firm brake pedal before moving it. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Service and Repair > Removal Wheel Cover: Service and Repair Removal REMOVAL 1. Raise and support the vehicle so that tire and wheel assembly clears ground level. CAUTION: When removing the bolt-on wheel cover, do not attempt to pry the wheel cover off the wheel. It is held on by the wheel mounting nuts. 2. Remove the five wheel mounting (lug) nuts (3) from the wheel studs. While removing the nuts, hold the wheel cover (2) in place so it doesn't fall off when the last nut is removed. 3. Remove the wheel cover (2) using care not to let the tire and wheel assembly (1) fall off the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Service and Repair > Removal > Page 7135 Wheel Cover: Service and Repair Installation INSTALLATION WARNING: Installing wheels without good metal-to-metal contact with the mounting surface could cause loosening of the wheel mounting (lug) nuts. This could adversely affect the safety and handling of the vehicle. NOTE: Never use oil or grease on studs or wheel mounting (lug) nuts. 1. With the tire and wheel assembly (1) positioned on the wheel studs without the wheel mounting (lug) nuts installed, align the valve notch in the wheel cover with the valve stem on the wheel and install the wheel cover over the studs. NOTE: Always use the original (OEM) style wheel mounting (lug) nuts. Do not use replacement parts of lesser quality or substitute design. 2. Install and lightly snug all five wheel mounting (lug) nuts (3) Do not tighten at this time. 3. Lower the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Service and Repair > Removal > Page 7136 4. Progressively tighten all wheel mounting (lug) nuts in the proper sequence shown. Tighten the nuts to a final torque of 135 Nm (100 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Hub Nut Tightening Torque ................................................................................................................. .............................................................. 245 Nm (181 ft. lbs.) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications ALUMINUM WHEEL Progressively tighten all wheel mounting nuts in the proper sequence shown. Tighten nuts to a final torque of ............................................................................................................................................................ 135 Nm (100 ft. lbs.) STEEL WHEEL Progressively tighten all wheel mounting (lug) nuts in the proper sequence shown. Tighten the nuts to a final torque of ...................................................................................................................................................... 135 Nm (100 ft. lbs.) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Wheel Fastener: Service and Repair Front Removal REMOVAL NOTE: Use the following procedure to remove one of five studs on one wheel hub. 1. Access and remove front brake rotor. CAUTION: Do not hammer wheel mounting studs out of the hub. Damage to the wheel bearing will occur, leading to premature bearing failure. 2. Install Remover (3), Special Tool 8677, on the hub flange (1) and wheel stud (2). 3. Tighten the Remover, pushing the wheel mounting stud out the rear of the hub flange. When the shoulder of the stud is past the flange, remove the Remover from the hub. 4. Remove the stud from the hub flange. Installation INSTALLATION NOTE: Use the following procedure to install one of five studs on one wheel hub. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 7146 1. Install the NEW wheel mounting stud in the flange of the hub (2) from the rear. 2. Install several washers (1) and a standard wheel mounting (lug) nut (3) on the stud (4). Install the mounting nut so that the flat side of the nut is against the washers to eliminate any binding. 3. Tighten the wheel mounting nut. This will pull the wheel mounting stud into the hub flange. When the head of the stud is fully seated against the rear of the hub flange, remove the wheel mounting nut and washers. 4. Install the brake rotor and all components previously removed to access it. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 7147 Wheel Fastener: Service and Repair Rear Removal REMOVAL NOTE: Use the following procedure to remove one of five studs on one wheel hub. 1. If equipped with rear disc brakes, access and remove brake rotor. 2. If equipped with rear drum brakes, access and remove brake drum. CAUTION: Do not hammer wheel mounting studs out of the hub. Damage to the wheel bearing will occur, leading to premature bearing failure. 3. Install Remover (1), Special Tool 8677, on the hub flange (2) and wheel stud (3). 4. Rotate the hub around until an open spot is found directly behind the wheel stud. 5. Tighten the Remover, pushing the wheel mounting stud out the rear of the hub flange. When the shoulder of the stud is past the flange, remove the Remover from the hub. 6. Remove the stud from the hub flange. Installation INSTALLATION NOTE: Use the following procedure to install one of five studs on one wheel hub. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 7148 1. Install the NEW wheel mounting stud in the flange of the hub (2) from the rear. 2. Install several washers (1) and a standard wheel mounting (lug) nut (3) on the stud (4). Install the mounting nut so that the flat side of the nut is against the washers to eliminate any binding. 3. Tighten the wheel mounting nut. This will pull the wheel mounting stud into the hub flange. When the head of the stud is fully seated against the rear of the hub flange, remove the wheel mounting nut and washers. 4. If equipped with rear disc brakes, install the brake rotor and all components previously removed to access it. 5. If equipped with rear drum brakes, install the brake drum and tire and wheel assembly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Description and Operation > Description Accumulator HVAC: Description and Operation Description DESCRIPTION To protect the A/C compressor from any liquid slugging, an A/C accumulator (1) is used in this A/C system to retain any refrigerant that may exit from the evaporator in a liquid state. The A/C accumulator is mounted below the engine compartment behind the right side of the front fascia. A band and mounting bracket (2) secures the A/C accumulator to the right front frame rail and the connections are sealed by use of metal gaskets (3) and rubber O-rings (4). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Description and Operation > Description > Page 7154 Accumulator HVAC: Description and Operation Operation OPERATION NOTE: Typical A/C accumulator shown. Refrigerant enters the A/C accumulator (1) mostly as a low pressure vapor through the inlet tube (2). Any liquid, oil-laden refrigerant falls to the bottom of the canister, which acts as a separator. A desiccant bag (3) is mounted inside the accumulator canister to absorb any moisture which may have entered and become trapped within the refrigerant system. A filter (4) is also mounted inside the canister to trap any foreign material that may have entered the refrigerant system during assembly. The low pressure vapor exits the A/C accumulator through the outlet tube (5). NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C accumulator has no serviceable parts except for the O-ring seals and gaskets. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals and gaskets must be replaced whenever the A/C accumulator is removed and installed. The A/C accumulator cannot be repaired and must be replaced if found to be leaking or damaged, or if an internal failure of the A/C compressor has occurred. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and Repair > Removal Accumulator HVAC: Service and Repair Removal REMOVAL WARNING: Review safety precautions and warnings before performing this procedure. Failure to follow the warnings and cautions could result in possible personal injury or death. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant system. 3. Raise and support the vehicle. 4. Remove the right front wheel. 5. Remove the three push-pin retainers (1) and three screws (2) that secure the front portion of the right front wheelhouse splash shield (3) to body (4) and position the front of the wheelhouse splash shield out of the way to gain access to the A/C accumulator. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and Repair > Removal > Page 7157 6. Remove the nut (7) that secures the lower A/C suction line (8) to the accumulator outlet tube (9) and disconnect the suction line from the accumulator tube. 7. Remove the bolt (5) and retaining band (6) that secure the A/C accumulator to the mounting bracket (10). 8. Remove the nut (3) that secures the upper A/C suction line (2) to the accumulator inlet tube (4) and disconnect the suction line from the accumulator tube. 9. If necessary remove the accumulator mounting bracket from the body. 10. Remove and discard the O-ring seals and gaskets and install plugs in, or tape over the opened refrigerant line fittings and the accumulator ports. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and Repair > Removal > Page 7158 Accumulator HVAC: Service and Repair Installation INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system. Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. CAUTION: The A/C accumulator must be replaced if an internal failure of the A/C compressor has occurred. Failure to replace the A/C accumulator can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. NOTE: If only the A/C accumulator is being replaced, add 30 milliliters (1.0 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. 1. If removed, install the accumulator mounting bracket (10). Tighten the retaining bolts to 15 Nm (11 ft. lbs.). 2. Remove the tape or plugs from all of the opened refrigerant line fittings and the accumulator ports. 3. Lubricate new rubber O-ring seals with clean refrigerant oil and install them and new gaskets onto the suction line and accumulator fittings. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Connect the upper A/C suction line (2) to the accumulator inlet tube (4) and install the retaining nut (3). Tighten the nut to 5 Nm (44 in. lbs.). 5. Install the retaining band (6) and bolt (5) that secure the A/C accumulator (1) to the mounting bracket. Tighten the bolt to 8 Nm (71 in. lbs.). 6. Connect the lower A/C suction line (8) to the accumulator outlet tube (9) and install the retaining nut (7). Tighten the nut to 5 Nm (44 in. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and Repair > Removal > Page 7159 7. Reposition the front of the right front wheel house splash shield (3) to the body (4) and install the three push-pin retainers (1) and the three screws (2). Tighten the screws securely. 8. Install the right front wheel. 9. Lower the vehicle. 10. Reconnect the negative battery cable. CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system. Failure to follow this caution will result in serious A/C compressor damage. 11. Evacuate the refrigerant system. 12. If the A/C accumulator is being replaced, add 30 milliliters (1.0 fluid ounce) of refrigerant oil to the refrigerant system. When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 13. Charge the refrigerant system. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations Air Door Actuator / Motor: Locations Component ID: 1 Component : ACTUATOR-RECIRCULATION DOOR Connector: Name : ACTUATOR-RECIRCULATION DOOR Color : BLACK # of pins : 6 Pin Description Circuit 1 RECIRCULATION DOOR DRIVER (A) C32 20DB/TN Pin Description Circuit 1 RECIRCULATION DOOR DRIVER (B) C132 20DB/GY 2-3-4-5-- 6 RECIRCULATION DOOR DRIVER (B) C132 20DB/GY 6 RECIRCULATION DOOR DRIVER (A) C32 20DB/TN Component Location - 25 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Page 7164 Component Location - 27 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Page 7165 Component Location - 31 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Page 7166 Component Location - 33 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Page 7167 Fig. 33 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Page 7168 Air Door Actuator / Motor: Diagrams Component ID: 1 Component : ACTUATOR-RECIRCULATION DOOR Connector: Name : ACTUATOR-RECIRCULATION DOOR Color : BLACK # of pins : 6 Pin Description Circuit 1 RECIRCULATION DOOR DRIVER (A) C32 20DB/TN Pin Description Circuit 1 RECIRCULATION DOOR DRIVER (B) C132 20DB/GY 2-3-4-5-- 6 RECIRCULATION DOOR DRIVER (B) C132 20DB/GY 6 RECIRCULATION DOOR DRIVER (A) C32 20DB/TN Component Location - 25 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Page 7169 Component Location - 27 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Page 7170 Component Location - 31 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Page 7171 Component Location - 33 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Page 7172 Fig. 33 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Description Air Door Actuator / Motor: Description and Operation Description DESCRIPTION The recirculation door actuator (1) is a reversible, 12 volt direct current (DC) servo motor, which is connected directly to the pivot shaft lever of the recirculation-air door. The recirculation door actuator is located on the right side of the HVAC air inlet housing. The recirculation door actuator is contained within a black molded plastic housing with an integral wire connector receptacle (2), an output shaft with splines (3) that connect it to the recirculation door and three integral mounting tabs (4) that allow the actuator to be secured to the air inlet housing. The recirculation door actuator does not require mechanical indexing to the recirculation-air door, as it is electronically calibrated by the A/C-heater control. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Description > Page 7175 Air Door Actuator / Motor: Description and Operation Operation OPERATION The recirculation door actuator is connected to the A/C-heater control through the vehicle electrical system by a dedicated two-wire lead and connector of the instrument panel wire harness. The recirculation door actuator can move the recirculation-air door in two directions. When the A/C-heater control pulls the voltage on one side of the motor connection high and the other connection low, the recirculation-air door will move in one direction. When the A/C-heater control reverses the polarity of the voltage to the motor, the recirculation-air door moves in the opposite direction. Once the A/C-heater control makes the voltage to both connections high or both connections low, the recirculation-air door stops and will not move. The A/C-heater control uses a pulse-count positioning system to monitor the operation and relative position of the recirculation door actuator and the recirculation-air door. The A/C-heater control learns the recirculation-air door stop positions during the calibration procedure and will store a diagnostic trouble code (DTC) for any problems it detects in the recirculation door actuator circuits. The recirculation door actuator cannot be adjusted or repaired and it must be replaced if found inoperative or damaged. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Removal Air Door Actuator / Motor: Service and Repair Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. NOTE: Illustration shown with instrument panel removed for clarity. NOTE: LHD model shown. RHD model similar. 1. Disconnect and isolate the negative battery cable. 2. Remove the glove box bin. 3. Reach through the glove box opening in the instrument panel and remove the screws (1) that secure the recirculation door actuator (2) to the right side of the HVAC air inlet housing (3). 4. Disconnect the wire harness connector (4) from the recirculation door actuator and remove the actuator. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Removal > Page 7178 Air Door Actuator / Motor: Service and Repair Installation INSTALLATION NOTE: Illustrations shown with instrument panel removed for clarity. NOTE: LHD model shown. RHD model similar. 1. Position the recirculation door actuator (1) to the right side of the HVAC air inlet housing (2). 2. Install the recirculation door actuator onto the air inlet housing. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft (3) with those on the recirculation door pivot shaft adapter (4). 3. Install the screws (1) that secure the recirculation door actuator (2) to the air inlet housing (3). Tighten the screws to 2 Nm (17 in. lbs.). 4. Connect the instrument panel wire harness connector (4) to the recirculation door actuator. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Removal > Page 7179 5. Install the glove box bin. 6. Reconnect the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Cable-Mode Door Air Door Cable: Service and Repair Cable-Mode Door Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. NOTE: Illustration shown with instrument panel removed for clarity. NOTE: LHD model shown. RHD model similar. 1. Disconnect and isolate the negative battery cable. NOTE: To aid in reinstallation, note the installed position of the mode control cable to the A/C-heater control prior to removal of the cable. 2. Remove the instrument panel center bezel and disconnect the mode control cable from the A/C-heater control. 3. On LHD models, remove the glove box. 4. Disengage the metal retaining clip (1) that secures the mode control cable (2) from the right side of the HVAC air distribution housing (3). NOTE: To aid in reinstallation, note the position of the mode control cable as it passes through the instrument panel support prior to removal of the cable. 5. Disconnect the mode control cable from the mode door cam (4) and remove the cable from the vehicle. Installation INSTALLATION NOTE: Illustration shown with instrument panel removed for clarity. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Cable-Mode Door > Page 7184 NOTE: LHD model shown. RHD model similar. 1. Position the mode control cable (2) to the right side of the HVAC air distribution housing (3) through the opening in the instrument panel support. 2. Connect the mode control cable to the mode door cam (4). 3. Engage the metal retaining clip (1) to the right side of the HVAC air distribution housing. Make sure the retaining clip is fully engaged to the housing. 4. Connect the mode door control cable to the A/C-heater control and install the instrument panel center bezel. 5. Visually verify the mode door cam moves from the full defrost position to the full panel position and then back to the full defrost position using the mode control knob on the A/C-heater control. If OK, go to step 10. If not OK, proceed to step 6. CAUTION: Failure to adjust the mode control cable when required can result in operating modes not being properly obtained. 6. Disengage the mode control cable from the metal retaining clip located on the right side of the HVAC housing. 7. Turn the mode control knob on the A/C-heater control to the full defrost position. 8. Reach behind the instrument panel and turn the mode door cam clockwise until it stops in the full defrost position and engage the mode control cable to the metal retaining clip. Make sure the cam is in the full defrost position and that the cable is fully engaged to the retaining clip. 9. Verify the mode door cam moves from the full defrost position to the full panel position and then back to the full defrost position as selected with the mode control knob on the A/C-heater control. If not, repeat steps 6 thru 9. 10. On LHD models, install the glove box. 11. Reconnect the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Cable-Mode Door > Page 7185 Air Door Cable: Service and Repair Cable-Temperature Control Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. NOTE: Illustration shown with instrument panel removed for clarity. NOTE: LHD model shown. RHD model similar. 1. Disconnect and isolate the negative battery cable. NOTE: To aid in reinstallation, note the installed position of the temperature control cable to the A/C-heater control prior to removal of the cable. 2. Remove the instrument panel center bezel and disconnect the temperature control cable from the A/C-heater control. 3. On RHD models, remove the glove box. 4. Disengage the metal retaining clip (1) that secures the temperature control cable (2) from the left side of the HVAC air distribution housing (3). NOTE: To aid in reinstallation, note the position of the temperature control cable as it passes through the instrument panel support prior to removal of the cable. 5. Disconnect the temperature control cable from the blend door pivot lever (4) and remove the cable from the vehicle. Installation INSTALLATION NOTE: Illustration shown with instrument panel removed for clarity. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Cable-Mode Door > Page 7186 NOTE: LHD model shown. RHD model similar. 1. Position the temperature control cable (2) to the left side of the HVAC air distribution housing (3) through the opening in the instrument panel support. 2. Connect the temperature control cable to the blend door pivot lever (4). 3. Engage the metal retaining clip (1) to the left side of the air distribution housing. Make sure the retaining clip is fully engaged to the housing. 4. Connect the temperature door control cable to the A/C-heater control and install the instrument panel center bezel. 5. Visually verify that the blend door pivot lever moves from the full hot position to the full cold position and then back to the full hot position using the temperature control knob on the A/C-heater control. If OK, go to step 10. If not OK, proceed to step 6. CAUTION: Failure to adjust the temperature control cable can result in full heating or cooling capabilities not being obtained. 6. Disengage the temperature control cable from the metal retaining clip located on the left side of the HVAC housing. 7. Turn the temperature control knob on the A/C-heater control to the full hot position. 8. Reach behind the instrument panel and move the blend door pivot lever forward until it stops in the full hot position and engage the temperature control cable to the metal retaining clip. Make sure the lever is in the full hot position and that the cable is fully engaged to the retaining clip. 9. Verify that the blend door pivot lever moves from the full hot position to the full cold position and then back to the full hot position, as selected with the temperature control knob on the A/C-heater control. If not, repeat steps 6 thru 9. 10. On RHD models, install the glove box. 11. Reconnect the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Description and Operation Air Duct: Description and Operation DESCRIPTION NOTE: LHD model shown. RHD model similar. There is one defroster air outlet (2) located on the top of the instrument panel (1). The airflow from the defroster outlet is directed by fixed vanes in the outlet and cannot be adjusted. The defroster air outlet is not serviceable from the instrument panel cover. There are two side window demister air outlets (4). One located on each end of the instrument panel top cover. The airflow from the side window demister air outlets is directed by fixed vanes in the outlets and cannot be adjusted. The side window demister air outlets are not serviceable from the instrument panel top cover. There are four rectangular instrument panel air outlets (5). One air outlet is located near each outboard end of the instrument panel facing the rear of the vehicle and two air outlets are located at the top of the instrument panel center bezel. Each of the instrument panel air outlets contain movable vanes that can direct or shut off the flow of the conditioned air leaving each of the instrument panel outlets. The driver and passenger side air instrument panel air outlets can be serviced separately. The center outlets are only serviced with the center bezel. A cooled beverage storage bin, located in the top of the glove box (6) is standard on vehicles equipped with A/C. Vehicles so equipped have an outlet which, when opened with the A/C on, allows cooled air to flow into the bin. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Beverage Cooler Air Outlet Air Duct: Service and Repair Beverage Cooler Air Outlet Removal BEVERAGE COOLER NOTE: LHD model shown. RHD model similar. 1. Remove the instrument panel top cover (1). 2. Disconnect the hose (2) from the beverage cooler outlet (3). 3. To disengage the four retaining tabs (4), slide the beverage cooler outlet toward the center of the cover and remove the outlet. Installation BEVERAGE COOLER NOTE: LHD model shown. RHD model similar. 1. Position the beverage cooler outlet (3) to the top of the storage bin and engage the four retaining tabs (4) by sliding the outlet toward the center of the instrument panel top cover (1). Make sure the tabs are fully engaged. 2. Connect the hose (2) to the beverage cooler outlet. 3. Install the instrument panel top cover. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Beverage Cooler Air Outlet > Page 7192 Air Duct: Service and Repair Defroster Duct Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. NOTE: LHD model shown. RHD model similar. NOTE: Illustration shown with instrument panel removed from vehicle for clarity. 1. Remove the instrument panel top cover. 2. Disconnect the left demister duct (7) and the right demister duct (5) from the defroster duct (2). 3. Remove the two screws (3) that secure the defroster duct to the defroster duct support (4). 4. Remove the two screws (1) that secure the defroster duct support to the instrument panel (6) and position the support out of the way. 5. Remove the defroster duct from the instrument panel. Installation INSTALLATION NOTE: LHD model shown. RHD model similar. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Beverage Cooler Air Outlet > Page 7193 NOTE: Illustration shown with instrument panel removed from vehicle for clarity. 1. Position the defroster duct (2) to the front of the instrument panel (6). 2. Reposition the defroster duct support (4) to the instrument panel and install the two retaining screws (1). Tighten the screws to 3 Nm (27 in. lbs.). 3. Install the two screws (3) that secure the defroster duct to the defroster duct support. Tighten the screws to 2.2 Nm (20 in. lbs.). 4. Connect the left demister duct (7) and the right demister duct (5) to the defroster duct. 5. Install the instrument panel top cover. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Beverage Cooler Air Outlet > Page 7194 Air Duct: Service and Repair Floor Distribution Ducts Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in an accidental airbag deployment and possible personal injury or death. RIGHT FRONT FLOOR DUCT NOTE: LHD model shown. RHD model similar. 1. Remove the instrument panel. 2. Disconnect the right floor duct (1) from the right side of the HVAC housing (2) and remove the duct. LEFT FRONT FLOOR DUCT NOTE: Illustration shown with instrument panel removed for clarity. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Beverage Cooler Air Outlet > Page 7195 NOTE: LHD model shown. RHD model similar. 3. On LHD models, remove the steering column opening cover. 4. On RHD models, remove the instrument panel cover. 5. Remove the screw that secures the left floor distribution duct (1) to the left side of the HVAC housing (2) and disconnect the duct from the housing outlet. REAR FLOOR DISTRIBUTION DUCTS 6. Remove the instrument panel. 7. Remove the rear seat floor ducts. 8. Disconnect the left rear floor distribution duct (1) and the right rear floor distribution duct (2) as required from the HVAC housing (3) and remove the duct(s). REAR SEAT FLOOR DUCTS NOTE: Right side rear floor duct shown. Left side duct similar. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Beverage Cooler Air Outlet > Page 7196 NOTE: LHD model shown. RHD model similar. 9. Remove the center floor console. 10. Remove the front seat from the side of the vehicle being serviced. 11. Pull the carpet back to gain access to the rear seat floor duct (2). 12. Remove the screw (1) and disengage the retainer that secures the rear seat floor duct to the floor support (4). 13. Disconnect the rear seat floor duct from the rear floor distribution duct (3) and remove the rear seat duct(s). Installation INSTALLATION RIGHT FRONT FLOOR DUCT Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Beverage Cooler Air Outlet > Page 7197 NOTE: LHD model shown. RHD model similar. 1. Connect the right front floor duct (1) to the right side of the HVAC housing (2). Make sure the duct is fully engaged to the housing. 2. Install the instrument panel. LEFT FRONT FLOOR DUCT NOTE: Illustration shown with instrument panel removed for clarity. NOTE: LHD model shown. RHD model similar. 3. Connect the left front floor duct (1) to the left side of the HVAC housing (2). Make sure the duct is fully engaged to the housing. 4. Install the screw that secures the left front floor duct to the left side of the HVAC housing. Tighten the screw to 2 Nm (17 in. lbs.). 5. On LHD models, install the steering column opening cover. 6. On RHD models, install the instrument panel cover. REAR FLOOR DISTRIBUTION DUCTS 7. Connect the left rear floor distribution duct (1) and the right rear floor distribution duct (2) as required to the HVAC housing (3). Make sure the ducts are fully engaged to the housing. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Beverage Cooler Air Outlet > Page 7198 8. Install the rear seat floor ducts. 9. Install the instrument panel. REAR SEAT FLOOR DUCTS NOTE: Right side rear floor duct shown. Left side duct similar. NOTE: LHD model shown. RHD model similar. 10. Connect the rear seat floor duct (2) to the rear floor distribution duct (3). Make sure the ducts are fully engaged to each other. 11. Engage the retainer that secures the rear seat floor duct to the floor support (4) and install the retaining screw (1). Tighten the screw to 2.2 Nm (20 in. lbs.). 12. Reinstall the carpet. 13. Install the front seat to the side of the vehicle being serviced. 14. Install the center floor console. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Beverage Cooler Air Outlet > Page 7199 Air Duct: Service and Repair Instrument Panel Duct Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. NOTE: Illustrations shown with instrument panel removed from vehicle for clarity. LEFT AND RIGHT SIDE DUCT NOTE: The left and right side instrument panel ducts are serviced only as an assembly with the left or right side demister duct. NOTE: LHD model shown. RHD model similar. 1. Remove the instrument panel top cover. 2. Disconnect the left side demister hose (3) and right side demister hose (5) from the defroster duct (4). 3. Remove the screws (2) that secure each demister duct (1 and 6) to the instrument panel support. 4. Remove the push-pin fastener (8) that secures each instrument panel duct (7 and 10) to the instrument panel support. 5. Disconnect the left and right side instrument panel ducts from the center duct (9). 6. Remove the each instrument panel duct and demister duct as an assembly from the instrument panel. CENTER DUCT Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Beverage Cooler Air Outlet > Page 7200 NOTE: LHD model shown. RHD model similar. 7. Remove the left and right side instrument panel and demister ducts (1 and 2). 8. Remove the two screws (3) that secure the center instrument panel duct (4) to the instrument panel support. 9. Rotate and tilt the center duct as necessary to remove it from the instrument panel. Installation INSTALLATION NOTE: Illustrations shown with instrument panel removed from vehicle for clarity. LEFT AND RIGHT SIDE DUCT NOTE: The left and right side instrument panel ducts are serviced only as an assembly with the left or right side demister duct. NOTE: LHD model shown. RHD model similar. 1. Position the left and right side instrument panel ducts (7 and 10) and the left and right side demister ducts (1 and 6) onto the top of the instrument panel as assemblies. 2. Connect the left and right side instrument panel ducts to the center duct (9). Make sure the ducts are fully engaged to each other. 3. Install the push-pin fastener (8) that secures each instrument panel duct to the instrument panel support. 4. Install the screws (2) that secure each demister duct to the instrument panel support. Tighten the screws to 2.2 Nm (20 in. lbs.). 5. Connect the left and right side demister hoses (3 and 5) to the defroster duct (4). Make sure the hoses are fully engaged to the defroster and demister ducts. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Beverage Cooler Air Outlet > Page 7201 6. Install the instrument panel top cover. CENTER DUCT NOTE: LHD model shown. RHD model similar. 7. Position the center instrument panel duct (2) onto the top of instrument panel. Rotate and tilt the duct as necessary. 8. Install the two screws (3) that secure the center duct to the instrument panel support. Tighten the screws to 2.2 Nm (20 in. lbs.). 9. Install the left and right side instrument panel and demister ducts (1 and 2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Beverage Cooler Air Outlet > Page 7202 Air Duct: Service and Repair Removal BEVERAGE COOLER NOTE: LHD model shown. RHD model similar. 1. Remove the instrument panel top cover (1). 2. Disconnect the hose (2) from the beverage cooler outlet (3). 3. To disengage the four retaining tabs (4), slide the beverage cooler outlet toward the center of the cover and remove the outlet. Installation BEVERAGE COOLER NOTE: LHD model shown. RHD model similar. 1. Position the beverage cooler outlet (3) to the top of the storage bin and engage the four retaining tabs (4) by sliding the outlet toward the center of the instrument panel top cover (1). Make sure the tabs are fully engaged. 2. Connect the hose (2) to the beverage cooler outlet. 3. Install the instrument panel top cover. Removal Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Beverage Cooler Air Outlet > Page 7203 REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. NOTE: LHD model shown. RHD model similar. NOTE: Illustration shown with instrument panel removed from vehicle for clarity. 1. Remove the instrument panel top cover. 2. Disconnect the left demister duct (7) and the right demister duct (5) from the defroster duct (2). 3. Remove the two screws (3) that secure the defroster duct to the defroster duct support (4). 4. Remove the two screws (1) that secure the defroster duct support to the instrument panel (6) and position the support out of the way. 5. Remove the defroster duct from the instrument panel. Installation INSTALLATION NOTE: LHD model shown. RHD model similar. NOTE: Illustration shown with instrument panel removed from vehicle for clarity. 1. Position the defroster duct (2) to the front of the instrument panel (6). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Beverage Cooler Air Outlet > Page 7204 2. Reposition the defroster duct support (4) to the instrument panel and install the two retaining screws (1). Tighten the screws to 3 Nm (27 in. lbs.). 3. Install the two screws (3) that secure the defroster duct to the defroster duct support. Tighten the screws to 2.2 Nm (20 in. lbs.). 4. Connect the left demister duct (7) and the right demister duct (5) to the defroster duct. 5. Install the instrument panel top cover. Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in an accidental airbag deployment and possible personal injury or death. RIGHT FRONT FLOOR DUCT NOTE: LHD model shown. RHD model similar. 1. Remove the instrument panel. 2. Disconnect the right floor duct (1) from the right side of the HVAC housing (2) and remove the duct. LEFT FRONT FLOOR DUCT NOTE: Illustration shown with instrument panel removed for clarity. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Beverage Cooler Air Outlet > Page 7205 NOTE: LHD model shown. RHD model similar. 3. On LHD models, remove the steering column opening cover. 4. On RHD models, remove the instrument panel cover. 5. Remove the screw that secures the left floor distribution duct (1) to the left side of the HVAC housing (2) and disconnect the duct from the housing outlet. REAR FLOOR DISTRIBUTION DUCTS 6. Remove the instrument panel. 7. Remove the rear seat floor ducts. 8. Disconnect the left rear floor distribution duct (1) and the right rear floor distribution duct (2) as required from the HVAC housing (3) and remove the duct(s). REAR SEAT FLOOR DUCTS NOTE: Right side rear floor duct shown. Left side duct similar. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Beverage Cooler Air Outlet > Page 7206 NOTE: LHD model shown. RHD model similar. 9. Remove the center floor console. 10. Remove the front seat from the side of the vehicle being serviced. 11. Pull the carpet back to gain access to the rear seat floor duct (2). 12. Remove the screw (1) and disengage the retainer that secures the rear seat floor duct to the floor support (4). 13. Disconnect the rear seat floor duct from the rear floor distribution duct (3) and remove the rear seat duct(s). Installation INSTALLATION RIGHT FRONT FLOOR DUCT Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Beverage Cooler Air Outlet > Page 7207 NOTE: LHD model shown. RHD model similar. 1. Connect the right front floor duct (1) to the right side of the HVAC housing (2). Make sure the duct is fully engaged to the housing. 2. Install the instrument panel. LEFT FRONT FLOOR DUCT NOTE: Illustration shown with instrument panel removed for clarity. NOTE: LHD model shown. RHD model similar. 3. Connect the left front floor duct (1) to the left side of the HVAC housing (2). Make sure the duct is fully engaged to the housing. 4. Install the screw that secures the left front floor duct to the left side of the HVAC housing. Tighten the screw to 2 Nm (17 in. lbs.). 5. On LHD models, install the steering column opening cover. 6. On RHD models, install the instrument panel cover. REAR FLOOR DISTRIBUTION DUCTS 7. Connect the left rear floor distribution duct (1) and the right rear floor distribution duct (2) as required to the HVAC housing (3). Make sure the ducts are fully engaged to the housing. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Beverage Cooler Air Outlet > Page 7208 8. Install the rear seat floor ducts. 9. Install the instrument panel. REAR SEAT FLOOR DUCTS NOTE: Right side rear floor duct shown. Left side duct similar. NOTE: LHD model shown. RHD model similar. 10. Connect the rear seat floor duct (2) to the rear floor distribution duct (3). Make sure the ducts are fully engaged to each other. 11. Engage the retainer that secures the rear seat floor duct to the floor support (4) and install the retaining screw (1). Tighten the screw to 2.2 Nm (20 in. lbs.). 12. Reinstall the carpet. 13. Install the front seat to the side of the vehicle being serviced. 14. Install the center floor console. Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. NOTE: Illustrations shown with instrument panel removed from vehicle for clarity. LEFT AND RIGHT SIDE DUCT NOTE: The left and right side instrument panel ducts are serviced only as an assembly with the left or right side demister duct. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Beverage Cooler Air Outlet > Page 7209 NOTE: LHD model shown. RHD model similar. 1. Remove the instrument panel top cover. 2. Disconnect the left side demister hose (3) and right side demister hose (5) from the defroster duct (4). 3. Remove the screws (2) that secure each demister duct (1 and 6) to the instrument panel support. 4. Remove the push-pin fastener (8) that secures each instrument panel duct (7 and 10) to the instrument panel support. 5. Disconnect the left and right side instrument panel ducts from the center duct (9). 6. Remove the each instrument panel duct and demister duct as an assembly from the instrument panel. CENTER DUCT NOTE: LHD model shown. RHD model similar. 7. Remove the left and right side instrument panel and demister ducts (1 and 2). 8. Remove the two screws (3) that secure the center instrument panel duct (4) to the instrument panel support. 9. Rotate and tilt the center duct as necessary to remove it from the instrument panel. Installation INSTALLATION NOTE: Illustrations shown with instrument panel removed from vehicle for clarity. LEFT AND RIGHT SIDE DUCT Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Beverage Cooler Air Outlet > Page 7210 NOTE: The left and right side instrument panel ducts are serviced only as an assembly with the left or right side demister duct. NOTE: LHD model shown. RHD model similar. 1. Position the left and right side instrument panel ducts (7 and 10) and the left and right side demister ducts (1 and 6) onto the top of the instrument panel as assemblies. 2. Connect the left and right side instrument panel ducts to the center duct (9). Make sure the ducts are fully engaged to each other. 3. Install the push-pin fastener (8) that secures each instrument panel duct to the instrument panel support. 4. Install the screws (2) that secure each demister duct to the instrument panel support. Tighten the screws to 2.2 Nm (20 in. lbs.). 5. Connect the left and right side demister hoses (3 and 5) to the defroster duct (4). Make sure the hoses are fully engaged to the defroster and demister ducts. 6. Install the instrument panel top cover. CENTER DUCT NOTE: LHD model shown. RHD model similar. 7. Position the center instrument panel duct (2) onto the top of instrument panel. Rotate and tilt the duct as necessary. 8. Install the two screws (3) that secure the center duct to the instrument panel support. Tighten the screws to 2.2 Nm (20 in. lbs.). 9. Install the left and right side instrument panel and demister ducts (1 and 2). Removal Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Beverage Cooler Air Outlet > Page 7211 REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. NOTE: The left and right side demister ducts are serviced only as an assembly with the left or right side instrument panel duct. NOTE: Illustration shown with instrument panel removed from vehicle for clarity. NOTE: LHD model shown. RHD model similar. 1. Remove the instrument panel top cover. 2. Disconnect the left side demister hose (3) and right side demister hose (5) from the defroster duct (4). 3. Remove the screws (2) that secure each demister duct (1 and 6) to the instrument panel support. 4. Remove the push-pin fastener (8) that secures each instrument panel duct (7 and 10) to the instrument panel support. 5. Disconnect the left and right side instrument panel ducts from the center duct (9). 6. Remove the each demister duct and instrument panel duct as an assembly from the instrument panel. Installation INSTALLATION NOTE: The left and right side demister ducts are serviced only as an assembly with the left or right side instrument panel duct. NOTE: Illustration shown with instrument panel removed from vehicle for clarity. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Beverage Cooler Air Outlet > Page 7212 NOTE: LHD model shown. RHD model similar. 1. Position the left and right side demister ducts (1 and 6) and the left and right side instrument panel ducts (7 and 10) onto the top of the instrument panel as assemblies. 2. Connect the left and right side instrument panel ducts to the center duct (9). Make sure the ducts are fully engaged to each other. 3. Install the push-pin fastener (8) that secures each instrument panel duct to the instrument panel support. 4. Install the screws (2) that secure each demister duct to the instrument panel support. Tighten the screws to 2.2 Nm (20 in. lbs.). 5. Connect the left and right side demister hoses (3 and 5) to the defroster duct (4). Make sure the hoses are fully engaged to the defroster and demister ducts. 6. Install the instrument panel top cover. Removal INSTRUMENT PANEL NOTE: Driver side air outlet shown. Passenger side outlet similar. NOTE: LHD model shown. RHD model similar. 1. Depending on the air outlet being serviced, remove the instrument cluster bezel or the center IP bezel. NOTE: If the foam seal on the air outlet is deformed or damaged, it must be replaced. 2. Remove the four screws (1) that secure the air outlet (2) to the bezel (3) and remove the outlet. Installation Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Beverage Cooler Air Outlet > Page 7213 INSTRUMENT PANEL NOTE: Driver side air outlet shown. Passenger side outlet similar. NOTE: LHD model shown. RHD model similar. 1. Position the air outlet (2) onto the bezel (3). 2. Install the four screws (1) that secure the air outlet to the bezel. Tighten the screws to 2 Nm (17 in. lbs.). 3. Depending on the outlet being serviced, install the instrument cluster bezel or the passenger side IP bezel. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Temperature Sensor / Switch HVAC: Locations Component ID: 282 Component : SENSOR-AMBIENT AIR TEMPERATURE Connector: Name : SENSOR-AMBIENT AIR TEMPERATURE Color : BLACK # of pins : 2 Pin Description Circuit 1 AAT SIGNAL G31 20VT/LG 2 AAT RETURN G931 20VT/DB Component Location - 10 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 7217 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 7218 Ambient Temperature Sensor / Switch HVAC: Diagrams Component ID: 282 Component : SENSOR-AMBIENT AIR TEMPERATURE Connector: Name : SENSOR-AMBIENT AIR TEMPERATURE Color : BLACK # of pins : 2 Pin Description Circuit 1 AAT SIGNAL G31 20VT/LG 2 AAT RETURN G931 20VT/DB Component Location - 10 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 7219 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation > Description Ambient Temperature Sensor / Switch HVAC: Description and Operation Description DESCRIPTION The ambient temperature sensor is a variable resistor type sensor. It is mounted to the lower front fascia behind the radiator grille and in front of the engine compartment. The ambient temperature sensor cannot be adjusted or repaired and, if inoperative or damaged, it must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation > Description > Page 7222 Ambient Temperature Sensor / Switch HVAC: Description and Operation Operation OPERATION The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal. The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the Totally Integrated Power Module (TIPM). Based upon the resistance in the sensor, the instrument cluster or Cab Compartment Node (CCN) display senses a specific voltage on the Controller Area Network (CAN) data bus circuit, which corresponds to a specific temperature. The compass/temperature display unit then displays the proper ambient temperature. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation > Page 7223 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection AMBIENT TEMPERATURE SENSOR The thermometer function is supported by the ambient temperature sensor, the Totally Integrated Power Module (TIPM), the Controller Area Network (CAN) data bus circuit, and the instrument cluster or Cab Compartment Node (CCN) compass/temperature display unit. If the display shows "O" (-45° C (-49° F)) or "SC" (60° C (140° F)), there is an OPEN or SHORT CIRCUIT that must be repaired. The ambient temperature sensor circuit can also be diagnosed using the following Sensor Test, and Sensor Circuit Test. If the temperature sensor and circuit are confirmed to be OK, but the temperature display is inoperative or incorrect, replace the instrument cluster or CCN assembly. SENSOR TESTING 1. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. 2. Disconnect the ambient temperature sensor wire harness connector. 3. Measure the resistance of the ambient temperature sensor. At room temperature (approx. 20° C (68° F)), the sensor resistance should be between 9-11 Kilohms (9000-11000 ohms). The sensor resistance should read between these two values. If OK, refer to the appropriate diagnostic information to continue diagnosis of the Totally Integrated Power Module (TIPM), the Controller Area Network (CAN) data bus circuit, and the instrument cluster or CCN. If not OK, replace the inoperative ambient temperature sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Service and Repair > Removal Ambient Temperature Sensor / Switch HVAC: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the belly pan. 3. Disconnect the wire harness connector (1) from the ambient temperature sensor (2). 4. Remove the fastener that secures the ambient temperature sensor bracket to the front fascia. 5. Remove the ambient temperature sensor from the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Service and Repair > Removal > Page 7226 Ambient Temperature Sensor / Switch HVAC: Service and Repair Installation INSTALLATION 1. Position the ambient temperature sensor in the vehicle. 2. Install the fastener that secures the ambient temperature sensor to the front fascia. 3. Connect the wire harness connector (1) to the ambient temperature sensor (2). 4. Install the belly pan. 5. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor: > 24-007-06 > Nov > 06 > A/C - Noise From Glove Box Area With Blower ON Blower Motor: Customer Interest A/C - Noise From Glove Box Area With Blower ON NUMBER: 24-007-06 GROUP: Heating & A/C DATE: November 11, 2006 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL NOVEMBER 27, 2006. SUBJECT: Noisy Blower Motor Due To Debris Ingestion OVERVIEW: This bulletin involves installing a screen to the recirculation door. MODELS: 2007 (PM) Caliber 2007 (MK49) Compass NOTE: This bulletin applies to vehicles built prior to September 6, 2006 (MDH 0906XX) without sales code JMA. SYMPTOM/CONDITION: The vehicle operator may notice an objectionable sound from the glove box area when blower motor is on. DIAGNOSIS: Operate the blower motor at a medium speed with windows closed. If the objectionable sound can be detected perform Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Disconnect and isolate the negative battery cable. 2. If equipped, remove the silencer from below the passenger side of the instrument panel. NOTE: The blower motor is located on the bottom of the passenger side of the HVAC housing. The blower motor can be removed from the vehicle without having to remove the HVAC housing. 3. From underneath the instrument panel, disengage the connector lock and disconnect the instrument panel wire harness connector from the blower motor (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor: > 24-007-06 > Nov > 06 > A/C - Noise From Glove Box Area With Blower ON > Page 7235 4. Remove the three screws that secure the blower motor and the wire lead bracket (if equipped) to the bottom of the HVAC housing and remove the blower motor (Fig. 1). NOTE: LHD model shown. RHD model similar. 5. Clean any debris out of the blower motor. It may be necessary to use shop air to blow it out of the blower motor. 6. Install the blower motor by positioning the blower motor onto the bottom of the HVAC housing. 7. Install the three screws that secure the blower motor and the wire lead bracket (if equipped) to the HVAC housing. Tighten the screws to 1.2 N.m (10 in. lbs.). 8. Connect the instrument panel wire harness connector to the blower motor and engage the connector lock. 9. If equipped, install the silencer below the passenger side of the instrument panel. 10. Open the glove box and carefully use fingers to press inward on the glove box open stops at the top of the bin, to allow the glove box to rotate down toward the carpet. 11. Rotate the box down and release the door hinges at the bottom and remove the glove box. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor: > 24-007-06 > Nov > 06 > A/C - Noise From Glove Box Area With Blower ON > Page 7236 12. Disengage the two retaining tabs that secure the particulate air filter cover to the passenger side of the HVAC housing and remove the cover (Fig. 2). NOTE: There will not be a particulate air filter installed on the vehicle. NOTE: LHD model shown in illustrations. RHD model similar. 13. Is the vehicle a Caliber (PM)? a. YES - Refer to Step # 17 b. No - Refer to Step # 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor: > 24-007-06 > Nov > 06 > A/C - Noise From Glove Box Area With Blower ON > Page 7237 14. Install a recirculation door screen (pin 68018099AA or 68018098AA) onto the recirculation door opening. Engage screen into all four mount holes (Fig. 3). 15. Position the particulate air filter cover to the HVAC housing and engage the two retaining tabs that secure the cover to the housing. Make sure the retaining tabs are fully engaged (Fig. 2). 16. Install the glove box. Repair Complete. 17. Cut the top two tabs off of the recirculation door screen (Fig. 4). 18. Install a piece of foam tape (pin 05019057AA) to the recirculation door screen all along the top header (Fig. 4). 19. Slide the recirculation door screen (pin 68018099AA or 68018098AA) above the particulate air filter cover opening and onto the recirculation Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor: > 24-007-06 > Nov > 06 > A/C - Noise From Glove Box Area With Blower ON > Page 7238 door opening. Engage screen into two bottom mount holes only (Fig. 3) and (Fig. 4). 20. Position the particulate air filter cover to the HVAC housing and engage the two retaining tabs that secure the cover to the housing. Make sure the retaining tabs are fully engaged (Fig. 2). 21. Install the glove box. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor: > 24-007-06 > Nov > 06 > A/C - Noise From Glove Box Area With Blower ON Blower Motor: All Technical Service Bulletins A/C - Noise From Glove Box Area With Blower ON NUMBER: 24-007-06 GROUP: Heating & A/C DATE: November 11, 2006 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL NOVEMBER 27, 2006. SUBJECT: Noisy Blower Motor Due To Debris Ingestion OVERVIEW: This bulletin involves installing a screen to the recirculation door. MODELS: 2007 (PM) Caliber 2007 (MK49) Compass NOTE: This bulletin applies to vehicles built prior to September 6, 2006 (MDH 0906XX) without sales code JMA. SYMPTOM/CONDITION: The vehicle operator may notice an objectionable sound from the glove box area when blower motor is on. DIAGNOSIS: Operate the blower motor at a medium speed with windows closed. If the objectionable sound can be detected perform Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Disconnect and isolate the negative battery cable. 2. If equipped, remove the silencer from below the passenger side of the instrument panel. NOTE: The blower motor is located on the bottom of the passenger side of the HVAC housing. The blower motor can be removed from the vehicle without having to remove the HVAC housing. 3. From underneath the instrument panel, disengage the connector lock and disconnect the instrument panel wire harness connector from the blower motor (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor: > 24-007-06 > Nov > 06 > A/C - Noise From Glove Box Area With Blower ON > Page 7244 4. Remove the three screws that secure the blower motor and the wire lead bracket (if equipped) to the bottom of the HVAC housing and remove the blower motor (Fig. 1). NOTE: LHD model shown. RHD model similar. 5. Clean any debris out of the blower motor. It may be necessary to use shop air to blow it out of the blower motor. 6. Install the blower motor by positioning the blower motor onto the bottom of the HVAC housing. 7. Install the three screws that secure the blower motor and the wire lead bracket (if equipped) to the HVAC housing. Tighten the screws to 1.2 N.m (10 in. lbs.). 8. Connect the instrument panel wire harness connector to the blower motor and engage the connector lock. 9. If equipped, install the silencer below the passenger side of the instrument panel. 10. Open the glove box and carefully use fingers to press inward on the glove box open stops at the top of the bin, to allow the glove box to rotate down toward the carpet. 11. Rotate the box down and release the door hinges at the bottom and remove the glove box. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor: > 24-007-06 > Nov > 06 > A/C - Noise From Glove Box Area With Blower ON > Page 7245 12. Disengage the two retaining tabs that secure the particulate air filter cover to the passenger side of the HVAC housing and remove the cover (Fig. 2). NOTE: There will not be a particulate air filter installed on the vehicle. NOTE: LHD model shown in illustrations. RHD model similar. 13. Is the vehicle a Caliber (PM)? a. YES - Refer to Step # 17 b. No - Refer to Step # 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor: > 24-007-06 > Nov > 06 > A/C - Noise From Glove Box Area With Blower ON > Page 7246 14. Install a recirculation door screen (pin 68018099AA or 68018098AA) onto the recirculation door opening. Engage screen into all four mount holes (Fig. 3). 15. Position the particulate air filter cover to the HVAC housing and engage the two retaining tabs that secure the cover to the housing. Make sure the retaining tabs are fully engaged (Fig. 2). 16. Install the glove box. Repair Complete. 17. Cut the top two tabs off of the recirculation door screen (Fig. 4). 18. Install a piece of foam tape (pin 05019057AA) to the recirculation door screen all along the top header (Fig. 4). 19. Slide the recirculation door screen (pin 68018099AA or 68018098AA) above the particulate air filter cover opening and onto the recirculation Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor: > 24-007-06 > Nov > 06 > A/C - Noise From Glove Box Area With Blower ON > Page 7247 door opening. Engage screen into two bottom mount holes only (Fig. 3) and (Fig. 4). 20. Position the particulate air filter cover to the HVAC housing and engage the two retaining tabs that secure the cover to the housing. Make sure the retaining tabs are fully engaged (Fig. 2). 21. Install the glove box. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Page 7248 Blower Motor: Locations Component ID: 167 Component : MOTOR-BLOWER Connector: Name : MOTOR-BLOWER Color : NATURAL # of pins : 2 Pin Description Circuit 1 BLOWER MOTOR HIGH SPEED C70 12DB/YL 2 BLOWER MOTOR CONTROL C7 12DB/PK Component Location - 25 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Page 7249 Component Location - 27 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Page 7250 Component Location - 31 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Page 7251 Component Location - 33 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Page 7252 Fig. 33 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions Blower Motor: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: Provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7255 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7256 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7257 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7258 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7259 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7260 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7261 5. Release the Secondary Terminal Lock, if required (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7262 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7263 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7264 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7265 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7266 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7267 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7268 Blower Motor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7269 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7270 STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7271 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7272 Blower Motor: Connector Views Component ID: 167 Component : MOTOR-BLOWER Connector: Name : MOTOR-BLOWER Color : NATURAL # of pins : 2 Pin Description Circuit 1 BLOWER MOTOR HIGH SPEED C70 12DB/YL 2 BLOWER MOTOR CONTROL C7 12DB/PK Component Location - 25 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7273 Component Location - 27 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7274 Component Location - 31 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7275 Component Location - 33 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7276 Fig. 33 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Description Blower Motor: Description and Operation Description DESCRIPTION The blower motor (1) is used to control the velocity of air moving through the HVAC housing by spinning the blower wheel (2) within the HVAC air inlet housing at the selected speed. The blower motor is a 12-volt, direct current (DC) motor mounted within a plastic housing with an integral wire harness connector (3) and three mounting tabs (4). The squirrel cage-type blower wheel is secured to the blower motor shaft and is positioned within the air inlet housing on the passenger side of the HVAC housing. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Description > Page 7279 Blower Motor: Description and Operation Operation OPERATION The blower motor is used to control the velocity of air moving through the HVAC housing by spinning the blower wheel within the HVAC air inlet housing at the selected speed. The blower motor will operate whenever the ignition switch is in the Run position and the blower motor control is in any position except Off. The blower motor receives battery current through the totally integrated power module (TIPM) whenever the ignition switch is in the Run position. Blower motor speed is controlled by regulating the ground path through or around the blower motor resistor and through the blower motor control located within the A/C-heater control. The blower motor can be accessed for service from underneath the instrument panel. NOTE: The blower motor is supplied with a 12V feed from the TIPM, through the blower motor resistor, whenever the ignition switch is in the RUN position. Due to an open circuit condition within the blower motor control switch the TIPM is UNABLE to detect an OPEN circuit for the blower motor. The blower motor control system is diagnosed using a scan tool. The blower motor and blower motor wheel are factory balanced as an assembly and cannot be adjusted or repaired and must be replaced if found inoperative or damaged. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Page 7280 Blower Motor: Testing and Inspection BLOWER MOTOR WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. NOTE: The blower motor is supplied with a 12 V feed from the TIPM, through the blower motor resistor, whenever the ignition switch is in the RUN position. Due to an open circuit condition within the blower motor control switch the TIPM is UNABLE to detect an OPEN circuit for the blower motor. To determine if an open condition exists within the blower motor circuit wiring, it is necessary to disconnect the negative battery cable and check for continuity within the blower motor circuits using an ohmmeter. For circuit descriptions and diagrams, refer to Air Conditioning/Heater in Wiring Diagrams. OPERATION Possible causes of an inoperative blower motor include: - Open fuse - Inoperative blower motor resistor - Inoperative blower motor switch - Inoperative blower motor - Inoperative blower motor circuit wiring or wire harness connectors NOISE To determine if the blower motor is the source of the noise, simply switch the blower motor from Off to On. To verify that the blower motor is the source of the noise, unplug the blower motor wire harness connector and operate the heater-A/C system. If the noise goes away, possible causes include: - Foreign material on fresh air inlet screen - Foreign material in blower wheel - Foreign material in HVAC housing - Improper blower motor mounting - Deformed or damaged blower wheel - Worn blower motor bearings or brushes VIBRATION Possible causes of a blower motor vibration include: - Improper blower motor mounting - Foreign material in blower wheel - Deformed or damaged blower wheel - Worn blower motor bearings Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Removal Blower Motor: Service and Repair Removal REMOVAL NOTE: The blower motor is located on the bottom of the passenger side of the HVAC housing. The blower motor can be removed from the vehicle without having to remove the HVAC housing. NOTE: LHD model shown. RHD model similar. 1. Disconnect and isolate the negative battery cable. 2. If equipped, remove the silencer from below the passenger side of the instrument panel. 3. From underneath the instrument panel, disengage the connector lock and disconnect the instrument panel wire harness connector (1) from the blower motor (2). 4. Remove the three screws (3) that secure the blower motor and the wire lead bracket (4) (if equipped) to the bottom of the HVAC housing (5) and remove the blower motor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Removal > Page 7283 Blower Motor: Service and Repair Installation INSTALLATION NOTE: LHD model shown. RHD model similar. 1. Position the blower motor (2) into the bottom of the HVAC housing (5). 2. Install the three screws (3) that secure the blower motor and the wire lead bracket (4) (if equipped) to the HVAC housing. Tighten the screws to 1.2 Nm (10 in. lbs.). 3. Connect the instrument panel wire harness connector (1) to the blower motor and engage the connector lock. 4. If equipped, install the silencer below the passenger side of the instrument panel. 5. Reconnect the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations Blower Motor Resistor: Locations Component ID: 186 Component : RESISTOR-BLOWER MOTOR Connector: Name : RESISTOR-BLOWER MOTOR Color : GRAY # of pins : 4 Pin Description Circuit 1 BLOWER MOTOR HIGH SPEED C70 12DB/YL 2 FRONT BLOWER M1 SPEED C72 18DB/OR 3 FRONT BLOWER M2 SPEED C73 18DB/VT 4 FRONT BLOWER LOW SPEED C71 18DB/BR Component Location - 25 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 7287 Component Location - 27 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 7288 Component Location - 31 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 7289 Component Location - 33 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 7290 Fig. 33 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 7291 Blower Motor Resistor: Diagrams Component ID: 186 Component : RESISTOR-BLOWER MOTOR Connector: Name : RESISTOR-BLOWER MOTOR Color : GRAY # of pins : 4 Pin Description Circuit 1 BLOWER MOTOR HIGH SPEED C70 12DB/YL 2 FRONT BLOWER M1 SPEED C72 18DB/OR 3 FRONT BLOWER M2 SPEED C73 18DB/VT 4 FRONT BLOWER LOW SPEED C71 18DB/BR Component Location - 25 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 7292 Component Location - 27 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 7293 Component Location - 31 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 7294 Component Location - 33 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 7295 Fig. 33 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Description and Operation > Description Blower Motor Resistor: Description and Operation Description DESCRIPTION The blower motor resistor is mounted to the HVAC housing on the passenger side of the vehicle. The blower motor resistor consists of a molded plastic mounting plate (1) with an integral wire connector receptacle (2). Concealed behind the mounting plate are resistors (3) located between a two-piece stamped steel base (4). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Description and Operation > Description > Page 7298 Blower Motor Resistor: Description and Operation Operation OPERATION The blower motor resistor is connected to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The blower motor resistor has three resistors, each of which will reduce the current flow through the blower motor to change the blower motor speed. The blower motor control for the heating-A/C system directs the ground path for the blower motor through the correct resistor to obtain the selected speed. With the blower motor control in the lowest speed position, the ground path for the blower motor is applied through all of the resistors. Each higher speed selected with the blower motor control applies the blower motor ground path through fewer of the resistors, increasing the blower motor speed. When the blower motor control is in the highest speed position, the blower motor resistor is bypassed and the blower motor receives a direct path to ground. The blower motor resistor cannot be adjusted or repaired and it must be replaced if found inoperative or damaged. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Description and Operation > Page 7299 Blower Motor Resistor: Testing and Inspection BLOWER MOTOR RESISTOR WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. NOTE: For circuit descriptions and diagrams, refer to WIRING DIAGRAM INFORMATION. The wiring information includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds. 1. Disconnect and isolate the negative battery cable. 2. Disconnect the wire harness connector from the blower motor resistor. 3. Using an ohmmeter, check for continuity between all of the blower motor resistor terminals. In each case there should be continuity. If OK, repair the wire harness circuits between the blower motor speed control and the blower motor resistor or blower motor as required. If not OK, replace the inoperative blower motor resistor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Removal Blower Motor Resistor: Service and Repair Removal REMOVAL WARNING: The blower motor resistor may get very hot during normal operation. If the blower motor was turned on prior to servicing the blower motor resistor, wait five minutes to allow the blower motor resistors to cool before performing diagnosis or service. Failure to take this precaution can result in possible personal injury. CAUTION: Do not operate the blower motor with the blower motor resistor removed from the circuit. Failure to take this precaution can result in vehicle damage. NOTE: LHD model shown. RHD model similar. 1. Disconnect and isolate the negative battery cable. 2. Disconnect the wire harness connector (1) from the blower motor resistor (2) located at the bottom of the HVAC housing (3) on the passenger side of the vehicle. 3. Remove the two screws (4) that secure the blower motor resistor to the HVAC housing and remove the resistor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Removal > Page 7302 Blower Motor Resistor: Service and Repair Installation INSTALLATION NOTE: LHD model shown. RHD model similar. 1. Position the blower motor resistor (2) onto the bottom of the HVAC housing (3). 2. Install the two screws (4) that secure the blower motor resistor to the HVAC housing. Tighten the screws to 1.2 Nm (10 in. lbs.). 3. Connect the wire harness connector (1) to the blower motor resistor. 4. Reconnect the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Description and Operation Cabin Air Filter: Description and Operation DESCRIPTION Some models are equipped with a particulate air filter (1) that helps purify the outside air entering the HVAC housing. The filter is mounted in the passenger compartment, behind the glove box bin. The filter should be replaced at least once a year or every 24,000 km (15,000 miles) and checked if heating-A/C system performance seems lower than expected. The particulate air filter is labeled with an arrow (2) to indicate the direction of air flow through the filter. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and Repair > Procedures Cabin Air Filter: Procedures REMOVAL NOTE:LHD model shown in illustrations. RHD model similar. NOTE:Illustration shown with instrument panel removed for clarity. 1. Remove the glove box bin. 2. Disengage the two retaining tabs (1) that secure the particulate air filter cover (2) to the passenger side of the HVAC housing (3) and remove the cover. 3. Remove the particulate air filter (1) from the HVAC housing (2) by pulling the filter element straight out of the housing. INSTALL NOTE:The particulate air filter is labeled with an arrow to indicate air flow direction through the filter. Make sure to properly install the particulate air filter. Failure to properly install the filter will result in the need to replace the filter sooner than required by design. NOTE:LHD model shown in illustrations. RHD model similar. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and Repair > Procedures > Page 7308 1. Install the particulate air filter (1) into the filter opening in the HVAC housing (2). Insert the particulate air filter directly into the housing with the arrow on the filter pointing to the floor. 2. Position the particulate air filter cover (2) to the HVAC housing (3) and engage the two retaining tabs (1) that secure the cover to the housing. Make sure the retaining tabs are fully engaged. 3. Install the glove box bin Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and Repair > Procedures > Page 7309 Cabin Air Filter: Removal and Replacement Removal REMOVAL NOTE: LHD model shown in illustrations. RHD model similar. NOTE: Illustration shown with instrument panel removed for clarity. 1. Remove the glove box bin. 2. Disengage the two retaining tabs (1) that secure the particulate air filter cover (2) to the passenger side of the HVAC housing (3) and remove the cover. 3. Remove the particulate air filter (1) from the HVAC housing (2) by pulling the filter element straight out of the housing. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and Repair > Procedures > Page 7310 Installation INSTALLATION NOTE: The particulate air filter is labeled with an arrow to indicate air flow direction through the filter. Make sure to properly install the particulate air filter. Failure to properly install the filter will result in the need to replace the filter sooner than required by design. NOTE: LHD model shown in illustrations. RHD model similar. 1. Install the particulate air filter (1) into the filter opening in the HVAC housing (2). Insert the particulate air filter directly into the housing with the arrow on the filter pointing to the floor. 2. Position the particulate air filter cover (2) to the HVAC housing (3) and engage the two retaining tabs (1) that secure the cover to the housing. Make sure the retaining tabs are fully engaged. 3. Install the glove box bin. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Ventilation Grille > Component Information > Service and Repair > Removal Cabin Ventilation Grille: Service and Repair Removal SCREEN-AIR INLET NOTE: LHD model shown. RHD model similar. 1. Remove the cowl grille screen. 2. Disengage the three push-in retainers (1) that secure the HVAC housing air inlet screen (2) to the cowl panel (3) and remove the screen. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Ventilation Grille > Component Information > Service and Repair > Removal > Page 7315 Cabin Ventilation Grille: Service and Repair Installation SCREEN-AIR INLET NOTE: LHD model shown. RHD model similar. 1. Position the HVAC housing air inlet screen (2) to the cowl panel (3) and fully engage the three push-in retainers (1) that secure the screen to the panel. 2. Install the cowl grille screen. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Locations Compressor Clutch: Locations Component ID: 324 Component : SOLENOID-A/C COMPRESSOR Connector: Name : SOLENOID-A/C COMPRESSOR Color : BLACK # of pins : 2 Pin Description Circuit 1 FUSED MAIN RELAY OUTPUT F343 20BR/YL Pin Description Circuit 1 A/C COMPRESSOR CONTROL C27 20LB/WT 2 A/C COMPRESSOR CONTROL C27 20LB/WT 2 GROUND Z916 20BK Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Locations > Page 7320 Component Location - 18 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Locations > Page 7321 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Locations > Page 7322 Compressor Clutch: Diagrams Component ID: 324 Component : SOLENOID-A/C COMPRESSOR Connector: Name : SOLENOID-A/C COMPRESSOR Color : BLACK # of pins : 2 Pin Description Circuit 1 FUSED MAIN RELAY OUTPUT F343 20BR/YL Pin Description Circuit 1 A/C COMPRESSOR CONTROL C27 20LB/WT 2 A/C COMPRESSOR CONTROL C27 20LB/WT 2 GROUND Z916 20BK Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Locations > Page 7323 Component Location - 18 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Locations > Page 7324 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation > Description Condenser HVAC: Description and Operation Description DESCRIPTION NOTE: A/C condenser with automatic transmission cooler shown. A/C Condenser without cooler similar. The A/C condenser (1) is located in the front of the engine compartment behind the grille. The A/C condenser is a heat exchanger that allows the high-pressure refrigerant gas being discharged by the A/C compressor to give up its heat to the air passing over the condenser fins, which causes the refrigerant to cool and change to a liquid state. The A/C condenser is equipped with tapping blocks for the A/C discharge line and the A/C liquid line (2) and an integral automatic transmission cooler (3), when equipped with an automatic transaxle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation > Description > Page 7329 Condenser HVAC: Description and Operation Operation OPERATION When air passes through the fins of the A/C condenser, the high-pressure refrigerant gas within the A/C condenser gives up its heat. The refrigerant then condenses as it leaves the A/C condenser and becomes a high-pressure liquid. The volume of air flowing over the condenser fins is critical to the proper cooling performance of the A/C system. Therefore, it is important that there are no objects placed in front of the radiator grille openings at the front of the vehicle or foreign material on the condenser fins that might obstruct proper air flow. Also, any factory-installed air seals or shrouds must be properly reinstalled following radiator or A/C condenser service. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C condenser has no serviceable parts except for the O-ring seals and gaskets. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals and gaskets must be replaced whenever a refrigerant line is removed from the A/C condenser. The A/C condenser cannot be repaired and must be replaced if leaking or damaged. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > Removal Condenser HVAC: Service and Repair Removal REMOVAL WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death. CAUTION: Before removing the A/C condenser, note the location of each of the radiator/condenser air seals. These air seals are used to direct air through the A/C condenser and radiator. The air seals must be reinstalled in their proper locations in order for the A/C and engine cooling systems to perform as designed. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant system. 3. If equipped with the 2.0L diesel engine, remove the front fascia. NOTE: It is not necessary to remove the hood latch from the upper radiator support on gasoline engine equipped models for A/C condenser service. 4. If equipped with a gasoline engine, remove the upper radiator support and position it out of the way. 5. On gasoline engine equipped models, carefully push the radiator (1) slightly rearward to gain access to the A/C condenser (2). 6. Remove the nut (3) that secures the A/C discharge line (4) to the right side of the A/C condenser and remove and discard the O-ring seal and gasket. 7. Install plugs in, or tape over the opened discharge line fitting and the condenser inlet port. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > Removal > Page 7332 NOTE: Illustration shown with front fascia removed for clarity. 8. Raise and support the vehicle. NOTE: On gasoline engine equipped models, reach up through the opening in the bottom of the front fascia located in the right front corner of the vehicle to gain access to the A/C liquid line. 9. Remove the nut (1) that secures the A/C liquid line (2) to the right side of the A/C condenser (3). 10. Disconnect the A/C liquid line from the A/C condenser and remove and discard the O-ring seal and gasket. 11. Install plugs in, or tape over the opened liquid line fitting and the condenser outlet port. NOTE: Illustration shown with front fascia and diesel engine charge air cooler (CAC) (when equipped) removed for clarity. 12. Remove the two bolts (3) that secure the lower condenser brackets to the radiator (5). 13. Lower the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > Removal > Page 7333 14. If equipped, disconnect the automatic transmission cooler lines (2) from the left side of the A/C condenser (1). 15. If equipped with the 2.0L diesel engine, remove the charge air cooler (CAC). 16. Carefully lift the A/C condenser straight up and disengage the two upper condenser brackets (4) from the radiator and remove the condenser from the engine compartment. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > Removal > Page 7334 Condenser HVAC: Service and Repair Installation INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system. Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. NOTE: If only the A/C condenser is being replaced, add 20 milliliters (0.7 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: Illustration shown with front fascia and diesel engine charge air cooler (CAC) (when equipped) removed for clarity. 1. Carefully lower the A/C condenser (1) straight down in front of the radiator (5) and engage the upper condenser brackets (4) to the radiator. 2. If equipped with the 2.0L diesel engine, install the charge air cooler (CAC). 3. If equipped, connect the automatic transmission cooler lines (2) to the left side of the A/C condenser. 4. Raise and support the vehicle. 5. Install the two bolts (3) that secure the lower condenser brackets to the radiator. Tighten the bolts to 4.5 Nm (40 in. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > Removal > Page 7335 NOTE: Illustration shown with front fascia removed for clarity. NOTE: On gasoline engine equipped models, reach up through the opening in the bottom of the front fascia located in the right front corner of the vehicle to gain access to the A/C liquid line. 6. Remove the tape or plug from the liquid line fitting and the condenser outlet port. 7. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the liquid line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 8. Connect the A/C liquid line (2) to the A/C condenser (3) and install the retaining nut (1). Tighten the nut to 5 Nm (44 in. lbs.). 9. Lower the vehicle. 10. Remove the tape or plug from the discharge line fitting and the condenser inlet port. 11. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the discharge line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > Removal > Page 7336 vehicle. 12. On gasoline engine equipped models, carefully push the radiator (1) slightly rearward to gain access to the A/C condenser (2). 13. Connect the A/C discharge line (4) to the A/C condenser and install the retaining nut (3). Tighten the nut to 5 Nm (44 in. lbs.). 14. If equipped with a gasoline engine, reposition and install the upper radiator support. 15. If equipped with the 2.0L diesel engine, install the front fascia. 16. Reconnect the negative battery cable. CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system. Failure to follow this caution will result in serious A/C compressor damage. 17. Evacuate the refrigerant system. 18. If the A/C condenser is being replaced, add 20 milliliters (0.7 fluid ounce) of refrigerant oil to the refrigerant system. When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 19. Charge the A/C system. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations Control Assembly: Locations Component ID: 50 Component : CONTROL-A/C-HEATER Connector: Name : CONTROL-A/C-HEATER C1 Color : BLACK # of pins : 12 Pin Description Circuit 1 FUSED IGNITION SWITCH OUTPUT (RUN) F929 20PK/RD 2 PANEL LAMPS DRIVER E12 20OR/GY 3 RECIRCULATION DOOR DRIVER (B) C132 20DB/GY 4 RECIRCULATION DOOR DRIVER (A) C32 20DB/TN 5 A/C INDICATOR DRIVER C4 20LB/RD 6-7 GROUND Z936 20BK/LB 8-9 HVAC MUX RETURN C955 20LB/PK 10 - 11 HVAC MUX CONTROL C105 20LB/LG 12 REAR WINDOW DEFOGGER SWITCH SIGNAL C215 20LB/BK Component Location - 26 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Page 7340 Component Location - 32 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Page 7341 Connector: Name : CONTROL-A/C-HEATER C2 Color : BLACK # of pins : 5 Pin Description Circuit 1 BLOWER MOTOR HIGH SPEED C70 12DB/YL 2 FRONT BLOWER M2 SPEED C73 18DB/VT 3 FRONT BLOWER M1 SPEED C72 18DB/OR 4 FRONT BLOWER LOW SPEED C71 18DB/BR 5 GROUND Z936 18BK/LB Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Page 7342 Component Location - 26 Component Location - 32 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Page 7343 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions Control Assembly: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: Provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7346 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7347 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7348 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7349 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7350 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7351 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7352 5. Release the Secondary Terminal Lock, if required (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7353 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7354 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7355 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7356 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7357 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7358 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7359 Control Assembly: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7360 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7361 STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7362 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7363 Control Assembly: Connector Views Component ID: 50 Component : CONTROL-A/C-HEATER Connector: Name : CONTROL-A/C-HEATER C1 Color : BLACK # of pins : 12 Pin Description Circuit 1 FUSED IGNITION SWITCH OUTPUT (RUN) F929 20PK/RD 2 PANEL LAMPS DRIVER E12 20OR/GY 3 RECIRCULATION DOOR DRIVER (B) C132 20DB/GY 4 RECIRCULATION DOOR DRIVER (A) C32 20DB/TN 5 A/C INDICATOR DRIVER C4 20LB/RD 6-7 GROUND Z936 20BK/LB 8-9 HVAC MUX RETURN C955 20LB/PK 10 - 11 HVAC MUX CONTROL C105 20LB/LG 12 REAR WINDOW DEFOGGER SWITCH SIGNAL C215 20LB/BK Component Location - 26 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7364 Component Location - 32 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7365 Connector: Name : CONTROL-A/C-HEATER C2 Color : BLACK # of pins : 5 Pin Description Circuit 1 BLOWER MOTOR HIGH SPEED C70 12DB/YL 2 FRONT BLOWER M2 SPEED C73 18DB/VT 3 FRONT BLOWER M1 SPEED C72 18DB/OR 4 FRONT BLOWER LOW SPEED C71 18DB/BR 5 GROUND Z936 18BK/LB Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7366 Component Location - 26 Component Location - 32 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7367 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Page 7368 Control Assembly: Description and Operation DESCRIPTION NOTE: Typical A/C-heater control shown. The A/C-heater control (1) for the manual temperature control (MTC) single zone system allows one temperature setting for the entire vehicle. All controls are identified by ISO graphic symbols. The heating-A/C system uses a combination of electrical and cable operated controls. These controls provide the vehicle operator with a number of setting options to help control the climate and comfort within the vehicle. The A/C-heater control is located in the instrument panel and contains: - a rotary control for mode control of the discharged air (2). - a rotary control for blower motor speed selection and to turn the blower motor off (3). - a rotary control for temperature control of the discharged air (4). - a push-button control to turn the rear window defogger system on and off (5). - a push-button control for recirculation control of the discharged air (6). - a push-button control to turn the A/C system on and off (7). The A/C-heater control cannot be repaired or adjusted and it must be replaced if found inoperative or damaged. The control knobs for the A/C-heater control are available for service replacement. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Removal Control Assembly: Service and Repair Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. NOTE: Typical A/C-heater control and center bezel shown. 1. Disconnect and isolate the negative battery cable. 2. Remove the center bezel (7) from the instrument panel and disconnect the wiring connector for the clock, power window switches and the accessory switches, as equipped. NOTE: To aid in reinstallation, note the installed positions of the control cables prior to removal. 3. Using a small screwdriver or similar tool, disengage the retaining clips that secure the control cables (1 and 9) to the back of the A/C-heater control (8). 4. Using a small screwdriver or similar tool, disengage the retaining clips that secure the control cables to the mode control sector gear (2) and the temperature control sector gear (5). 5. Disconnect the wire harness connectors (3 and 4) from the rear of the A/C-heater control and place the center bezel on a work bench. 6. Remove the four screws (6) that secure the A/C-heater control to the back of the center bezel and remove the control. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Removal > Page 7371 Control Assembly: Service and Repair Installation INSTALLATION NOTE: Typical A/C-heater control and center bezel shown. 1. Install the A/C-heater control (8) into the instrument panel center bezel (7). 2. Install the four screws (6) that secure the A/C-heater control to the center bezel. Tighten the screws to 2 Nm (17 in. lbs.). 3. Position the center bezel to the instrument panel and connect the wire harness connectors (3 and 4) to the back of the A/C-heater control. NOTE: Install the mode control cable onto the A/C heater control first. Then install the temperature control cable. 4. Connect the control cables (1 and 9) to the mode door control sector gear (2) and the temperature control sector gear (5) and fully engage the retaining clips. Make sure the retaining clips are fully engaged to the sector gears. 5. Connect the control cables to the back of the A/C-heater control and fully engage the retaining clips. Make sure the retaining clips are fully engaged to the back of the A/C-heater control. 6. Connect the wire harness connectors to the accessory switches, power window switches and clock, as equipped and install the center bezel. 7. Reconnect the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Description Evaporator Core: Description and Operation Description DESCRIPTION NOTE: LHD model shown. RHD model similar. The A/C evaporator (1) for the heating-A/C system is mounted in the HVAC housing, which is located behind the instrument panel. The A/C evaporator and its insulator (2) are positioned within the HVAC housing so that all air entering the housing must pass over the evaporator fins before it is distributed through the heating-A/C system ducts and outlets. A tapping block (3) and O-ring seals are used to connect and seal the A/C evaporator tubes (4) to the underhood refrigerant lines. The A/C evaporator can only be serviced by removing and disassembling the HVAC housing assembly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Description > Page 7376 Evaporator Core: Description and Operation Operation OPERATION Refrigerant enters the A/C evaporator through the A/C orifice tube as a low-temperature, low-pressure mixture of liquid and gas. As air flows over the fins of the A/C evaporator, the humidity in the air condenses on the fins, and the heat from the air is absorbed by the refrigerant. Heat absorption causes the refrigerant to boil and vaporize. The refrigerant becomes a low-pressure gas when it leaves the A/C evaporator. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C evaporator has no serviceable parts except for the O-ring seals. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever a refrigerant line is removed from the A/C evaporator. The A/C evaporator cannot be repaired and must be replaced if found to be leaking or damaged. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Removal Evaporator Core: Service and Repair Removal REMOVAL NOTE: The HVAC housing assembly must be removed from vehicle and disassembled for service of the A/C evaporator. NOTE: LHD model shown. RHD model similar. 1. Remove the HVAC housing and place it on a workbench. 2. Disassemble the HVAC housing to gain access to the A/C evaporator. NOTE: If the foam insulator around the A/C evaporator is deformed or damaged, the insulator must be replaced. 3. Carefully lift the A/C evaporator (1) and the foam insulator (2) out of the lower half of the HVAC housing (3). NOTE: If the seal around the evaporator tube tapping block is deformed or damaged, the seal must be replaced. 4. If required, remove the seal (4) from around the evaporator tube tapping block (5). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Removal > Page 7379 Evaporator Core: Service and Repair Installation INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system. Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. NOTE: If only the A/C evaporator is being replaced, add 20 milliliters (0.7 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: LHD model shown. RHD model similar. 1. If removed, install the seal (4) onto the evaporator tube tapping block (5). NOTE: Make sure that the foam insulator is properly positioned in the HVAC housing. 2. Carefully install the A/C evaporator (1) and foam insulator (2) into the lower half of the HVAC housing (3). 3. Assemble the HVAC housing. 4. Install the HVAC housing. 5. If the A/C evaporator is being replaced, add 20 milliliters (0.7 fluid ounce) of refrigerant oil to the refrigerant system. When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Description and Operation Evaporator Drain Tube: Description and Operation DESCRIPTION Condensation that accumulates within the HVAC housing is drained through a port located at the bottom of the HVAC housing (1). A rubber condensation drain tube (2) is installed onto the drain port and protrudes through a rubber grommet (3) in the left side floor panel (4) to ensure that any condensate completely drains out of the HVAC housing and to the ground. NOTE: The condensation drain tube must be kept open to prevent water from collecting in the bottom of the HVAC housing. The drain tube is designed to keep contaminants from entering the HVAC housing. If the tube is pinched or blocked, condensate cannot drain, causing water to back up and spill into the passenger compartment. It is normal to see condensation drainage below the vehicle in warm weather. If the condensation drain tube is damaged or missing, it must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Service and Repair > Removal Evaporator Drain Tube: Service and Repair Removal REMOVAL 1. Pull back the floor carpet to gain access to the condensation drain tube (2) located on the left side of the vehicle at the front right of the foot well. 2. Disconnect the condensation drain tube from the bottom of the HVAC housing (1). 3. Remove the condensate drain tube from the rubber grommet (3) in the front floor panel (4). 4. If required, remove the rubber grommet from the floor panel. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Service and Repair > Removal > Page 7385 Evaporator Drain Tube: Service and Repair Installation INSTALLATION 1. If removed, install the rubber grommet (3) onto the driver side front floor panel (4). Make sure the grommet is fully engaged to the floor panel. 2. Connect the condensation drain tube (2) onto the drain port located on the bottom of the HVAC housing (1). 3. Install the condensation drain tube into the rubber grommet. 4. Reinstall the floor carpet. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations Component ID: 292 Component : SENSOR-EVAPORATOR TEMPERATURE Connector: Name : SENSOR-EVAPORATOR TEMPERATURE Color : NATURAL # of pins : 2 Pin Description Circuit 1 EVAPORATOR TEMPERATURE SENSOR SIGNAL C21 20DB/LG 2 SENSOR GROUND C121 20DB/DG Component Location - 23 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 7389 Fig. 23 Component Location - 24 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 7390 Component Location - 26 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 7391 Component Location - 29 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 7392 Fig. 29 Component Location - 30 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 7393 Component Location - 32 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 7394 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 7395 Evaporator Temperature Sensor / Switch: Diagrams Component ID: 292 Component : SENSOR-EVAPORATOR TEMPERATURE Connector: Name : SENSOR-EVAPORATOR TEMPERATURE Color : NATURAL # of pins : 2 Pin Description Circuit 1 EVAPORATOR TEMPERATURE SENSOR SIGNAL C21 20DB/LG 2 SENSOR GROUND C121 20DB/DG Component Location - 23 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 7396 Fig. 23 Component Location - 24 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 7397 Component Location - 26 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 7398 Component Location - 29 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 7399 Fig. 29 Component Location - 30 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 7400 Component Location - 32 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 7401 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Description Evaporator Temperature Sensor / Switch: Description and Operation Description DESCRIPTION The evaporator temperature sensor measures the temperature of the conditioned air downstream of the A/C evaporator. The evaporator temperature sensor is an electrical thermistor (1) mounted on the end of a molded plastic housing (2) that is inserted into the driver side of the HVAC housing near the coldest point of the A/C evaporator. The evaporator temperature sensor is retained in the HVAC housing by two integral retaining tabs (3) and is connected to the vehicle electrical system by use of a wire lead and connector (4) with two terminals. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Description > Page 7404 Evaporator Temperature Sensor / Switch: Description and Operation Operation OPERATION The evaporator temperature sensor monitors the surface temperature of A/C evaporator and supplies an input signal to the A/C-heater control. The A/C-heater control uses the evaporator temperature sensor input signal to optimize A/C system performance and to protect the A/C system from evaporator freezing. The evaporator temperature sensor will change its internal resistance in response to the temperatures it monitors and is connected to the A/C-heater control through sensor ground circuit and a 5-volt reference signal circuit. As the temperature of the A/C evaporator decreases, the internal resistance of the evaporator temperature sensor decreases. The A/C-heater control uses the monitored voltage reading as an indication of evaporator temperature. The A/C-heater control is programmed to respond to this input by requesting the powertrain control module (PCM) or the engine control module (ECM) (depending on engine application) to adjust the compressor swash plate angle as necessary to optimize A/C system performance and to protect the A/C system from evaporator freezing. The evaporator temperature sensor is diagnosed using a scan tool. The evaporator temperature sensor cannot be adjusted or repaired and it must be replaced if found inoperative or damaged. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Service and Repair > Removal Evaporator Temperature Sensor / Switch: Service and Repair Removal REMOVAL NOTE: Illustration shown with air distribution housing removed for clarity. NOTE: It is not necessary to remove and disassemble the HVAC housing to service the evaporator temperature sensor. The evaporator temperature sensor can be removed for service from underneath the instrument panel. 1. Disconnect and isolate the negative battery cable. 2. Reach up under the driver side of the instrument panel and disconnect the electrical connector for the evaporator temperature sensor (1) from the instrument panel wire harness. 3. Using needle nose pliers, disengage the two retaining tabs (3) that secure the evaporator temperature sensor to the HVAC housing (2) by carefully pulling the sensor straight out of the side of the HVAC housing. 4. Route the electrical connector and wire lead of the evaporator temperature sensor out from under the heater core tubes and remove the sensor from the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Service and Repair > Removal > Page 7407 Evaporator Temperature Sensor / Switch: Service and Repair Installation INSTALLATION NOTE: Illustration shown with air distribution housing removed for clarity. 1. Route the electrical connector and wire lead of the evaporator temperature sensor (1) under the heater core tubes located on the driver side of the HVAC housing (2). 2. Install the evaporator temperature sensor into the driver side of the HVAC housing. Make sure the retaining tabs (3) are fully engaged to the housing. 3. Connect the electrical connector for the evaporator temperature sensor to the instrument panel wire harness. 4. Reconnect the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Description and Operation > Description Expansion Block/Orifice Tube: Description and Operation Description DESCRIPTION The A/C orifice tube establishes the pressure differential between the high and low pressure sides of the A/C system by providing a restriction between the A/C condenser and the A/C evaporator. The A/C orifice tube in this vehicle is installed in the A/C liquid line and is of a variable orifice valve (VOV) design. The variable A/C orifice tube consists of the inlet filter screen (5), the bi-metal coil (4), the fixed port (3), the variable port (6), metering orifices (1), a nylon mesh diffuser screen (7) and two rubber O-rings (2) which seal the tube to the inside of the A/C liquid line to prevent refrigerant from bypassing the metering orifices. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Description and Operation > Description > Page 7412 Expansion Block/Orifice Tube: Description and Operation Operation OPERATION The variable A/C orifice tube provides improved A/C system cooling during city driving and when under heavy loads by controlling refrigerant flow through the two parallel flow paths integral to the orifice tube. Under normal loads, the refrigerant flows through the inlet filter screen, the fixed and variable ports and both metering orifices. As the load on the A/C system increases, the temperature of the refrigerant leaving the A/C condenser increases, which causes the bi-metal coil to expand and restrict the flow of refrigerant through the variable port of the tube. Restricting the flow of refrigerant through the variable port and its orifice provides a greater pressure differential between the high and low pressure sides of the A/C system, resulting in colder refrigerant vapor traveling through the A/C evaporator to help remove the heat from the conditioned air flowing into the passenger compartment. The A/C orifice tube is not serviceable and the A/C liquid line must be replaced if the orifice tube is found inoperative. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation > Description Heater Core: Description and Operation Description DESCRIPTION NOTE: LHD model shown. RHD model similar. The heater core (1) for the heating-A/C system is mounted within the HVAC air distribution housing, which is located behind the instrument panel. The heater core is a heat exchanger made of rows of tubes with fins and is positioned within the air distribution housing so that only the selected amount of air entering the housing passes through the heater core before it is distributed through the heating-A/C system ducts and outlets. One end of the heater core is fitted with a tank (2) that includes the fittings for the heater core tubes (3). The heater core can only be serviced by removing the HVAC housing from the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation > Description > Page 7417 Heater Core: Description and Operation Operation OPERATION Engine coolant is circulated through the heater hoses to the heater core at all times. As the coolant flows through the heater core, heat is removed from the engine and is transferred to the heater core tubes and fins. Air directed through the heater core picks up the heat from the heater core fins. The blend-air door allows control of the heater output air temperature by regulating the amount of air flowing through the heater core. The blower motor speed controls the volume of air flowing through the HVAC housing. The heater core cannot be repaired and it must be replaced if inoperative, leaking or damaged. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Installation Heater Core: Service and Repair Installation INSTALLATION NOTE: LHD model with A/C shown. RHD and heater-only models similar. 1. Carefully install the heater core (6) into the left side of the air distribution housing (5). 2. On RHD models, install the air distribution housing (5) onto the HVAC housing (9). 3. Install the retaining bracket (4) and screw (3) that secure the heater core tubes (8). Tighten the screw to 1.2 Nm (10 in. lbs.) 4. Install the flange (2) that secures the heater core tubes to the front of the HVAC housing. 5. Install the screw (10) that secures the flange to the HVAC housing. Tighten the screw to 1.2 Nm (10 in. lbs.). NOTE: If the foam seal for the flange is deformed or damaged, it must be replaced. 6. Install the foam seal (1) onto the flange. 7. Install the left side front floor duct. NOTE: If the heater core is being replaced, flush the cooling system. 8. Install the HVAC housing assembly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Installation > Page 7420 Heater Core: Service and Repair Removal REMOVAL NOTE: The HVAC housing assembly must be removed from vehicle for service of the heater core. NOTE: LHD model with A/C shown. RHD and heater-only models similar. 1. Remove the HVAC housing assembly and place it on a workbench. 2. Remove the left side front floor duct. NOTE: If the foam seal for the flange is deformed or damaged, it must be replaced. 3. Remove the foam seal (1) from the flange (2) located on the front of the HVAC housing (9). 4. Remove the screw (10) that secures the flange to the front of the HVAC housing and remove the flange. 5. Remove the screw (3) that secures the retaining bracket (4) for the heater core tubes (8) to the left side of the air distribution housing (5). 6. On RHD models, remove the air distribution housing from the HVAC housing. 7. Carefully pull the heater core (6) out of the driver side of the air distribution housing. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Description and Operation > Operation High Pressure Safety Valve HVAC: Description and Operation Operation HIGH PRESSURE RELIEF VALVE The high pressure relief valve vents refrigerant from the A/C system when a discharge pressure of 3445 to 4135 kPa (500 to 600 psi) or above is reached. The high pressure relief valve closes with a minimum discharge pressure of 2756 kPa (400 psi) is reached. The high pressure relief valve vents only enough refrigerant to reduce the A/C system pressure, and then re-seats itself. The majority of the refrigerant is conserved in the A/C system. If the high pressure relief valve vents refrigerant, it does not mean the valve is inoperative. The high pressure relief valve is factory-calibrated and cannot be adjusted or repaired, and must not be removed or otherwise disturbed. The valve is only serviced as a part of the A/C compressor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Description and Operation > Operation > Page 7425 High Pressure Safety Valve HVAC: Description and Operation Description HIGH PRESSURE RELIEF VALVE A high pressure relief valve is located on the compressor cylinder head at the rear of the A/C compressor. This mechanical valve is designed to vent refrigerant from the A/C system to protect against damage to the A/C compressor and other A/C system components caused by condenser air flow restriction or an overcharge of refrigerant. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service Precautions > Warning Hose/Line HVAC: Service Precautions Warning WARNING WARNING: The A/C system contains refrigerant under high pressure. Repairs should only be performed by qualified service personnel. Serious or fatal injury may result from improper service procedures. WARNING: Avoid breathing the refrigerant and refrigerant oil vapor or mist. Exposure may irritate the eyes, nose, and/or throat. Wear eye protection when servicing the A/C refrigerant system. Serious eye injury can result from direct contact with the refrigerant. If eye contact occurs, seek medical attention immediately. WARNING: Do not expose the refrigerant to open flame. Poisonous gas is created when refrigerant is burned. An electronic leak detector is recommended. Serious or fatal injury may result from improper service procedures. WARNING: If accidental A/C system discharge occurs, ventilate the work area before resuming service. Large amounts of refrigerant released in a closed work area will displace the oxygen and cause suffocation and serious or fatal injury. WARNING: The evaporation rate of R-134a refrigerant at average temperature and altitude is extremely high. As a result, anything that comes in contact with the refrigerant will freeze. Always protect the skin or delicate objects from direct contact with the refrigerant. WARNING: The R-134a service equipment or the vehicle refrigerant system should not be pressure tested or leak tested with compressed air. Some mixtures of air and R-134a have been shown to be combustible at elevated pressures. These mixtures are potentially dangerous, and may result in fire or explosion causing property damage and serious or fatal injury. WARNING: The engine cooling system is designed to develop internal pressures up to 145 kilopascals (21 pounds per square inch). Do not remove or loosen the coolant pressure cap, cylinder block drain plugs, radiator drain, radiator hoses, heater hoses, or hose clamps while the engine cooling system is hot and under pressure. Allow the vehicle to cool for a minimum of 15 minutes before opening the cooling system for service. Failure to observe this warning can result in serious burns from the heated engine coolant. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service Precautions > Warning > Page 7430 Hose/Line HVAC: Service Precautions Caution CAUTION CAUTION: Never add R-12 to a refrigerant system designed to use R-134a. Do not use R-12 equipment or parts on an R-134a A/C system. These refrigerants are not compatible and damage to the A/C system will result. CAUTION: Never use R-12 refrigerant oil in an A/C system designed to use R-134a refrigerant oil. These refrigerant oils are not compatible and damage to the A/C system will result. CAUTION: The use of A/C system sealers may result in damage to A/C refrigerant recovery/evacuation/recharging equipment and/or A/C system. Many federal, state/provincial and local regulations prohibit the recharge of A/C systems with known leaks. DaimlerChrysler recommends the detection of A/C system leaks through the use of approved leak detectors and fluorescent leak detection dyes. Vehicles found with A/C system sealers should be treated as contaminated and replacement of the entire A/C refrigerant system is recommended. A/C systems found to be contaminated with A/C system sealers, A/C stop-leak products or seal conditioners voids the warranty for the A/C system. CAUTION: Recover the refrigerant before opening any fitting or connection. Open the fittings with caution, even after the system has been discharged. Never open or loosen a connection before recovering the refrigerant. CAUTION: The internal parts of the A/C system will remain stable as long as moisture-free refrigerant and refrigerant oil is used. Abnormal amounts of dirt, moisture or air can upset the chemical stability. This may cause operational troubles or even serious damage if present in more than very small quantities. Before disconnecting a component, clean the outside of the fittings thoroughly to prevent contamination from entering the refrigerant system. Keep service tools and the work area clean. Do not open the refrigerant system or uncap a replacement component until you are ready to service the system. Immediately after disconnecting a component from the refrigerant system, seal the open fittings with a cap or plug. This will prevent contamination from entering the A/C system. CAUTION: Refrigerant oil will absorb moisture from the atmosphere if left uncapped. Do not open a container of refrigerant oil until you are ready to use it. Replace the cap on the oil container immediately after using. Store refrigerant oil only in a clean, airtight, and moisture-free container. CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system. Failure to follow this caution will result in serious A/C compressor damage. CAUTION: Do not overcharge the refrigerant system. Overcharging will cause excessive compressor head pressure and can cause compressor noise and A/C system failure. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line Hose/Line HVAC: Description and Operation A/C Discharge Line DESCRIPTION NOTE: A/C discharge line for gasoline engine shown in illustration. A/C discharge line for diesel engine similar. The A/C discharge line (1) is the refrigerant line that carries refrigerant from the A/C compressor to the A/C condenser and includes the high side service port (2) and a fitting (3) for the A/C pressure transducer (4). NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C discharge line has no serviceable parts except for the metal gaskets (5) and rubber O-ring seals (6) and the high side service port valve core. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals and gaskets must be replaced whenever the A/C discharge line is removed. The A/C discharge line cannot be repaired and must be replaced if found to be leaking or damaged. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line > Page 7433 Hose/Line HVAC: Description and Operation A/C Liquid Line DESCRIPTION The A/C liquid line (1) is the refrigerant line that carries refrigerant from the A/C condenser to the A/C evaporator. The A/C liquid line contains the low side service port (2) and the variable A/C orifice tube. The A/C liquid line is only serviced as an assembly with the upper A/C suction line (3). NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C liquid/suction line assembly has no serviceable parts except for the metal gaskets (4), rubber O-ring seals (5) and the low side service port valve core. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals and gaskets must be replaced whenever the A/C liquid/suction line assembly is removed. The A/C liquid/suction line assembly cannot be repaired and must be replaced if found to be leaking or damaged, or if an internal failure of the A/C compressor has occurred. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line > Page 7434 Hose/Line HVAC: Description and Operation A/C Suction Line DESCRIPTION The A/C suction line is serviced in two sections. The upper section of the A/C suction line (1) is the refrigerant line that carries refrigerant from the A/C evaporator to the A/C accumulator. The lower section of the A/C suction line (2) carries refrigerant from the A/C accumulator to the A/C compressor. The upper portion of the A/C suction line is only serviced as an assembly with the A/C liquid line (5). NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The lower A/C suction line and the A/C liquid/suction line assembly has no serviceable parts except for the rubber O-ring seals (3), metal gaskets (4) and the low side service port valve core. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals and gaskets must be replaced whenever the lower A/C suction line and/or the A/C liquid/suction line assembly is removed. The lower A/C suction line and the A/C liquid/suction line assembly cannot be repaired and must be replaced if found to be leaking or damaged. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line > Page 7435 Hose/Line HVAC: Description and Operation Plumbing Description DESCRIPTION The A/C refrigerant lines and hoses are used to carry the refrigerant between the various A/C system components. The refrigerant lines and hoses for the R-134a A/C system consist of a barrier-hose design with a nylon tube sandwiched between rubber layers. The nylon tube helps to contain the R-134a refrigerant, which has a small molecular structure. The ends of the refrigerant lines are made from lightweight aluminum and braze-less fittings. Any kinks or sharp bends in the refrigerant lines and hoses will reduce the capacity of the entire A/C system and can reduce the flow of refrigerant within the system. Operation OPERATION High pressures are produced in the refrigerant system when the A/C compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. Depending on vehicle, model and market application, refrigerant lines are connected to each other or other A/C system components with block-type or quick-connect type fittings. To ensure the integrity of the refrigerant system, flat gaskets and O-rings are used to seal the refrigerant system connections. The refrigerant lines and hoses cannot be repaired and must be replaced if leaking or damaged. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line Hose/Line HVAC: Service and Repair A/C Discharge Line Removal REMOVAL WARNING: Review safety precautions and warnings before performing this procedure. Failure to follow the warnings and cautions could result in possible personal injury or death. NOTE: It is not necessary to completely remove the front fascia for A/C discharge line service. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant system. 3. Raise and support the vehicle. 4. Remove the splash shield from the right side frame rail. 5. Remove the nut (1) that secures the A/C discharge line (2) to the A/C compressor (3). 6. Disconnect the A/C discharge line from the A/C compressor and remove and discard the O-ring seal and gasket. 7. Install plugs in, or tape over the opened discharge line fitting and the compressor port. 8. Lower the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 7438 9. Remove the upper radiator closure panel and carefully pull the top of the fascia forward to gain access to the A/C discharge line (3). 10. Reach down through the opening between the radiator and the front fascia and disconnect the wire harness connector (1) from the A/C pressure transducer (2). 11. Remove the nut (5) that secures the A/C discharge line to the right side of the A/C condenser (4). 12. Disconnect the A/C discharge line from the A/C condenser and remove and discard the O-ring seal and gasket. 13. Install plugs in, or tape over the discharge line fitting and the condenser port. 14. If necessary, remove the A/C pressure transducer from the A/C discharge line. Installation INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system. Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 7439 1. If removed, install the A/C pressure transducer (2) onto the A/C discharge line (3). Tighten the A/C pressure transducer securely. 2. Position the A/C discharge line into the engine compartment. 3. Remove the tape or plugs from the discharge line fitting and the condenser port. 4. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the discharge line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 5. Reach down through the opening between the radiator and the front fascia and connect the A/C discharge line to the A/C condenser (4). 6. Install the nut (5) that secures the A/C discharge line to the A/C condenser. Tighten the nut to 5 Nm (44 in. lbs.). 7. Connect the wire harness connector (1) to the A/C pressure transducer. 8. Install the upper radiator closure panel. 9. Raise and support the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 7440 10. Remove the tape or plugs from the discharge line fitting and the compressor port. 11. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the discharge line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 12. Connect the A/C discharge line (2) to the A/C compressor (3). 13. Install the nut (1) that secures the A/C discharge line to the A/C compressor. Tighten the nut to 20 Nm (15 ft. lbs.). 14. Install the splash shield onto the right side frame rail. 15. Lower the vehicle. 16. Reconnect the negative battery cable. CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system. Failure to follow this caution will result in serious A/C compressor damage. 17. Evacuate the refrigerant system. 18. Adjust the refrigerant oil level. 19. Charge the refrigerant system. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 7441 Hose/Line HVAC: Service and Repair A/C Liquid Line Removal REMOVAL WARNING: Review safety precautions and warnings before performing this procedure. Failure to follow the warnings and cautions could result in possible personal injury or death. NOTE: The A/C liquid line is only serviced as an assembly with the upper A/C suction line. NOTE: LHD model shown in illustrations. RHD model similar. NOTE: Illustration shown with front fascia removed for clarity. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant system. 3. Raise and support the vehicle. 4. Remove the A/C accumulator. 5. Reach up through the opening in the bottom of the front fascia located in the right front corner of the vehicle and remove the nut (3) that secures the A/C liquid line (1) to the A/C condenser (2). 6. Disconnect the A/C liquid line from the A/C condenser and remove and discard the O-ring seal and gasket. 7. Install plugs in, or tape over the opened refrigerant line fittings and the condenser and accumulator ports. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 7442 8. Lower the vehicle. 9. Remove the three nuts (1) that secure the heat shield (3) to the studs (2) located on the dash panel in the engine compartment and remove the heat shield. NOTE: It is only necessary to position the engine coolant reservoir and the power steering fluid reservoir out of the way. Draining of the coolant and brake fluid is not required when servicing the washer bottle. 10. Remove the windshield washer reservoir. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 7443 11. Remove the nut (1) that secures the refrigerant line retaining bracket (2) to the right front strut tower (5). 12. On RHD models, disengage the retainers that secure the power brake booster vacuum supply hose to the dash panel and position the vacuum line out of the way. 13. Remove the bolt (3) that secures the A/C liquid and suction line assembly (4) to the A/C evaporator (6). 14. Disconnect the A/C liquid and suction line assembly from the A/C evaporator and remove and discard the dual-plane seals. 15. Install plugs in, or tape over the opened refrigerant line fittings and the evaporator ports. 16. Remove the A/C liquid and suction line assembly from the engine compartment. Installation INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system. Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. CAUTION: The A/C liquid line must be replaced if an internal failure of the A/C compressor has occurred. Failure to replace the A/C liquid line can prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: LHD model shown in illustrations. RHD model similar. 1. Position the A/C liquid and suction line assembly (4) into the engine compartment. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 7444 2. Remove the tape or plugs from the refrigerant line fittings and the evaporator ports. 3. Lubricate the rubber O-rings on new dual-plane seals with clean refrigerant oil and install the seals onto the liquid and suction line fittings. Use only the specified seals as they are made of special materials compatible to the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Connect the A/C liquid and suction line assembly to the A/C evaporator (6). 5. Install the bolt (3) that secures the A/C liquid and suction line assembly to the A/C evaporator. Tighten the bolt to 12 Nm (105 in. lbs.). 6. On RHD models, engage the retainers that secure the power brake booster vacuum supply hose to the dash panel. 7. Install the nut (1) that secures the refrigerant line bracket (2) to the right front strut tower (5). Tighten the nut to 4.5 Nm (40 in. lbs.). 8. Install the windshield washer reservoir, power steering reservoir and the engine coolant reservoir. 9. Position the heat shield (3) onto the studs (2) located on the dash panel in the engine compartment. 10. Install the three nuts (1) that secure the heat shield to the dash panel. Tighten the nuts to 1 Nm (10 in. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 7445 NOTE: Illustration shown with front fascia removed for clarity. 11. Raise and support the vehicle. 12. Remove the tape or plugs from the liquid line fitting and the condenser port. 13. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the liquid line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 14. Reach up through the opening in the bottom of the front fascia and connect the A/C liquid line (1) to the A/C condenser (2) and install the retaining nut (3). Tighten the nut to 5 Nm (44 in. lbs.). 15. Install the A/C accumulator. 16. Lower the vehicle. 17. Reconnect the negative battery cable. CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system. Failure to follow this caution will result in serious A/C compressor damage. 18. Evacuate the refrigerant system. 19. Adjust the refrigerant oil level. 20. Charge the A/C system. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 7446 Hose/Line HVAC: Service and Repair A/C Suction Line Removal REMOVAL WARNING: Review safety precautions and warnings before performing this procedure. Failure to follow the warnings and cautions could result in possible personal injury or death. NOTE: The A/C suction line is serviced in two sections. The upper section of the A/C suction line is the refrigerant line that carries refrigerant from the A/C evaporator to the A/C accumulator. The lower section of the A/C suction line carries refrigerant from the A/C accumulator to the A/C compressor. NOTE: LHD model shown in illustrations. RHD model similar. Upper A/C Suction Line NOTE: The upper portion of the A/C suction line is only serviced as an assembly with the A/C liquid line. NOTE: Illustration shown with front fascia removed for clarity. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant system. 3. Raise and support the vehicle. 4. Remove the A/C accumulator. 5. Reach up through the opening in the bottom of the front fascia located in the right front corner of the vehicle and remove the nut (3) that secures the A/C liquid line (1) to the A/C condenser (2). 6. Disconnect the A/C liquid line from the A/C condenser and remove and discard the O-ring seal and gasket. 7. Install plugs in, or tape over the opened refrigerant line fittings and the condenser and accumulator ports. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 7447 8. Lower the vehicle. 9. Remove the three nuts (1) that secure the heat shield (3) to the studs (2) located on the dash panel in the engine compartment and remove the heat shield. NOTE: It is only necessary to position the engine coolant reservoir and the power steering fluid reservoir out of the way. Draining of the coolant and brake fluid is not required when servicing the washer bottle. 10. Remove the windshield washer reservoir. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 7448 11. Remove the nut (1) that secures the refrigerant line retaining bracket (2) to the right front strut tower (5). 12. On RHD models, disengage the retainers that secure the power brake booster vacuum supply hose to the dash panel and position the vacuum line out of the way. 13. Remove the bolt (3) that secures the A/C liquid and suction line assembly (4) to the A/C evaporator (6). 14. Disconnect the A/C liquid and suction line assembly from the A/C evaporator and remove and discard the dual-plane seals. 15. Install plugs in, or tape over the opened refrigerant line fittings and the evaporator ports. 16. Remove the A/C liquid and suction line assembly from the engine compartment. Lower A/C Suction Line 17. Disconnect and isolate the negative battery cable. 18. Recover the refrigerant from the refrigerant system. 19. Raise and support the vehicle. 20. Remove the right front wheel. 21. Remove the three push-pin retainers (1) and three screws (2) that secure the front portion of the right front wheelhouse splash shield (3) to body (4) and position the front of the wheelhouse splash shield out of the way to gain access to the A/C accumulator. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 7449 22. Remove the nut (2) that secures the lower A/C suction line (3) to the A/C accumulator (1). 23. Disconnect the lower A/C suction line from the A/C accumulator and remove and discard the O-ring seal and gasket. 24. Install plugs in, or tape over the opened suction line fitting and the accumulator port. 25. Remove the nut (1) that secures the lower A/C suction line (2) to the A/C compressor (3). 26. Disconnect the lower A/C suction line from the A/C compressor and remove and discard the O-ring seal and gasket. 27. Install plugs in, or tape over the opened suction line fitting and the compressor port. 28. Remove the lower A/C suction line from the engine compartment. Installation INSTALLATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 7450 CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system. Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: LHD model shown in illustrations. RHD model similar. Upper A/C Suction Line 1. Position the A/C liquid and suction line assembly (4) into the engine compartment. 2. Remove the tape or plugs from the refrigerant line fittings and the evaporator ports. 3. Lubricate the rubber O-rings on new dual-plane seals with clean refrigerant oil and install the seals onto the liquid and suction line fittings. Use only the specified seals as they are made of special materials compatible to the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Connect the A/C liquid and suction line assembly to the A/C evaporator (6). 5. Install the bolt (3) that secures the A/C liquid and suction line assembly to the A/C evaporator. Tighten the bolt to 12 Nm (105 in. lbs.). 6. On RHD models, engage the retainers that secure the power brake booster vacuum supply hose to the dash panel. 7. Install the nut (1) that secures the refrigerant line bracket (2) to the right front strut tower (5). Tighten the nut to 4.5 Nm (40 in. lbs.). 8. Install the windshield washer reservoir, power steering reservoir and the engine coolant reservoir. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 7451 9. Position the heat shield (3) onto the studs (2) located on the dash panel in the engine compartment. 10. Install the three nuts (1) that secure the heat shield to the dash panel. Tighten the nuts to 1 Nm (10 in. lbs.). NOTE: Illustration shown with front fascia removed for clarity. 11. Raise and support the vehicle. 12. Remove the tape or plugs from the liquid line fitting and the condenser port. 13. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the liquid line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 14. Reach up through the opening in the bottom of the front fascia and connect the A/C liquid line (1) to the A/C condenser (2) and install the retaining nut (3). Tighten the nut to 5 Nm (44 in. lbs.). 15. Install the A/C accumulator. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 7452 16. Lower the vehicle. 17. Reconnect the negative battery cable. 18. Evacuate the refrigerant system. 19. Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 20. Charge the A/C system. Lower A/C Suction Line 21. Position the lower A/C suction line (2) into the engine compartment. 22. Remove the tape or plugs from the suction line fitting and the compressor port. 23. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and new gasket onto the suction line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 24. Connect the lower A/C suction line to the A/C compressor (3). 25. Install the nut (1) that secures the A/C suction line to the A/C compressor. Tighten the nut to 20 Nm (15 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 7453 26. Remove the tape or plugs from the suction line fitting and the accumulator port. 27. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and new gasket onto the suction line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 28. Connect the lower A/C suction line (3) to the A/C accumulator (1). 29. Install the nut (2) that secures the lower A/C suction line to the A/C accumulator. Tighten the nut to 5 Nm (44 in. lbs.). 30. Reposition the front of the right front wheel house splash shield (3) to the body (4) and install the three push-pin retainers (1) and the three screws (2). Tighten the screws securely. 31. Install the right front wheel. 32. Lower the vehicle. 33. Reconnect the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 7454 CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system. Failure to follow this caution will result in serious A/C compressor damage. 34. Evacuate the refrigerant system. 35. Adjust the refrigerant oil level. 36. Charge the A/C system. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > Customer Interest for Housing Assembly HVAC: > 24-007-06 > Nov > 06 > A/C - Noise From Glove Box Area With Blower ON Housing Assembly HVAC: Customer Interest A/C - Noise From Glove Box Area With Blower ON NUMBER: 24-007-06 GROUP: Heating & A/C DATE: November 11, 2006 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL NOVEMBER 27, 2006. SUBJECT: Noisy Blower Motor Due To Debris Ingestion OVERVIEW: This bulletin involves installing a screen to the recirculation door. MODELS: 2007 (PM) Caliber 2007 (MK49) Compass NOTE: This bulletin applies to vehicles built prior to September 6, 2006 (MDH 0906XX) without sales code JMA. SYMPTOM/CONDITION: The vehicle operator may notice an objectionable sound from the glove box area when blower motor is on. DIAGNOSIS: Operate the blower motor at a medium speed with windows closed. If the objectionable sound can be detected perform Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Disconnect and isolate the negative battery cable. 2. If equipped, remove the silencer from below the passenger side of the instrument panel. NOTE: The blower motor is located on the bottom of the passenger side of the HVAC housing. The blower motor can be removed from the vehicle without having to remove the HVAC housing. 3. From underneath the instrument panel, disengage the connector lock and disconnect the instrument panel wire harness connector from the blower motor (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > Customer Interest for Housing Assembly HVAC: > 24-007-06 > Nov > 06 > A/C - Noise From Glove Box Area With Blower ON > Page 7463 4. Remove the three screws that secure the blower motor and the wire lead bracket (if equipped) to the bottom of the HVAC housing and remove the blower motor (Fig. 1). NOTE: LHD model shown. RHD model similar. 5. Clean any debris out of the blower motor. It may be necessary to use shop air to blow it out of the blower motor. 6. Install the blower motor by positioning the blower motor onto the bottom of the HVAC housing. 7. Install the three screws that secure the blower motor and the wire lead bracket (if equipped) to the HVAC housing. Tighten the screws to 1.2 N.m (10 in. lbs.). 8. Connect the instrument panel wire harness connector to the blower motor and engage the connector lock. 9. If equipped, install the silencer below the passenger side of the instrument panel. 10. Open the glove box and carefully use fingers to press inward on the glove box open stops at the top of the bin, to allow the glove box to rotate down toward the carpet. 11. Rotate the box down and release the door hinges at the bottom and remove the glove box. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > Customer Interest for Housing Assembly HVAC: > 24-007-06 > Nov > 06 > A/C - Noise From Glove Box Area With Blower ON > Page 7464 12. Disengage the two retaining tabs that secure the particulate air filter cover to the passenger side of the HVAC housing and remove the cover (Fig. 2). NOTE: There will not be a particulate air filter installed on the vehicle. NOTE: LHD model shown in illustrations. RHD model similar. 13. Is the vehicle a Caliber (PM)? a. YES - Refer to Step # 17 b. No - Refer to Step # 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > Customer Interest for Housing Assembly HVAC: > 24-007-06 > Nov > 06 > A/C - Noise From Glove Box Area With Blower ON > Page 7465 14. Install a recirculation door screen (pin 68018099AA or 68018098AA) onto the recirculation door opening. Engage screen into all four mount holes (Fig. 3). 15. Position the particulate air filter cover to the HVAC housing and engage the two retaining tabs that secure the cover to the housing. Make sure the retaining tabs are fully engaged (Fig. 2). 16. Install the glove box. Repair Complete. 17. Cut the top two tabs off of the recirculation door screen (Fig. 4). 18. Install a piece of foam tape (pin 05019057AA) to the recirculation door screen all along the top header (Fig. 4). 19. Slide the recirculation door screen (pin 68018099AA or 68018098AA) above the particulate air filter cover opening and onto the recirculation Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > Customer Interest for Housing Assembly HVAC: > 24-007-06 > Nov > 06 > A/C - Noise From Glove Box Area With Blower ON > Page 7466 door opening. Engage screen into two bottom mount holes only (Fig. 3) and (Fig. 4). 20. Position the particulate air filter cover to the HVAC housing and engage the two retaining tabs that secure the cover to the housing. Make sure the retaining tabs are fully engaged (Fig. 2). 21. Install the glove box. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Housing Assembly HVAC: > 24-007-06 > Nov > 06 > A/C Noise From Glove Box Area With Blower ON Housing Assembly HVAC: All Technical Service Bulletins A/C - Noise From Glove Box Area With Blower ON NUMBER: 24-007-06 GROUP: Heating & A/C DATE: November 11, 2006 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL NOVEMBER 27, 2006. SUBJECT: Noisy Blower Motor Due To Debris Ingestion OVERVIEW: This bulletin involves installing a screen to the recirculation door. MODELS: 2007 (PM) Caliber 2007 (MK49) Compass NOTE: This bulletin applies to vehicles built prior to September 6, 2006 (MDH 0906XX) without sales code JMA. SYMPTOM/CONDITION: The vehicle operator may notice an objectionable sound from the glove box area when blower motor is on. DIAGNOSIS: Operate the blower motor at a medium speed with windows closed. If the objectionable sound can be detected perform Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Disconnect and isolate the negative battery cable. 2. If equipped, remove the silencer from below the passenger side of the instrument panel. NOTE: The blower motor is located on the bottom of the passenger side of the HVAC housing. The blower motor can be removed from the vehicle without having to remove the HVAC housing. 3. From underneath the instrument panel, disengage the connector lock and disconnect the instrument panel wire harness connector from the blower motor (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Housing Assembly HVAC: > 24-007-06 > Nov > 06 > A/C Noise From Glove Box Area With Blower ON > Page 7472 4. Remove the three screws that secure the blower motor and the wire lead bracket (if equipped) to the bottom of the HVAC housing and remove the blower motor (Fig. 1). NOTE: LHD model shown. RHD model similar. 5. Clean any debris out of the blower motor. It may be necessary to use shop air to blow it out of the blower motor. 6. Install the blower motor by positioning the blower motor onto the bottom of the HVAC housing. 7. Install the three screws that secure the blower motor and the wire lead bracket (if equipped) to the HVAC housing. Tighten the screws to 1.2 N.m (10 in. lbs.). 8. Connect the instrument panel wire harness connector to the blower motor and engage the connector lock. 9. If equipped, install the silencer below the passenger side of the instrument panel. 10. Open the glove box and carefully use fingers to press inward on the glove box open stops at the top of the bin, to allow the glove box to rotate down toward the carpet. 11. Rotate the box down and release the door hinges at the bottom and remove the glove box. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Housing Assembly HVAC: > 24-007-06 > Nov > 06 > A/C Noise From Glove Box Area With Blower ON > Page 7473 12. Disengage the two retaining tabs that secure the particulate air filter cover to the passenger side of the HVAC housing and remove the cover (Fig. 2). NOTE: There will not be a particulate air filter installed on the vehicle. NOTE: LHD model shown in illustrations. RHD model similar. 13. Is the vehicle a Caliber (PM)? a. YES - Refer to Step # 17 b. No - Refer to Step # 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Housing Assembly HVAC: > 24-007-06 > Nov > 06 > A/C Noise From Glove Box Area With Blower ON > Page 7474 14. Install a recirculation door screen (pin 68018099AA or 68018098AA) onto the recirculation door opening. Engage screen into all four mount holes (Fig. 3). 15. Position the particulate air filter cover to the HVAC housing and engage the two retaining tabs that secure the cover to the housing. Make sure the retaining tabs are fully engaged (Fig. 2). 16. Install the glove box. Repair Complete. 17. Cut the top two tabs off of the recirculation door screen (Fig. 4). 18. Install a piece of foam tape (pin 05019057AA) to the recirculation door screen all along the top header (Fig. 4). 19. Slide the recirculation door screen (pin 68018099AA or 68018098AA) above the particulate air filter cover opening and onto the recirculation Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Housing Assembly HVAC: > 24-007-06 > Nov > 06 > A/C Noise From Glove Box Area With Blower ON > Page 7475 door opening. Engage screen into two bottom mount holes only (Fig. 3) and (Fig. 4). 20. Position the particulate air filter cover to the HVAC housing and engage the two retaining tabs that secure the cover to the housing. Make sure the retaining tabs are fully engaged (Fig. 2). 21. Install the glove box. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > Page 7476 Housing Assembly HVAC: Description and Operation DESCRIPTION NOTE: LHD model shown RHD model similar. All models are equipped with a common HVAC housing assembly that combines A/C and heating capabilities into a single unit mounted within the passenger compartment. The HVAC housing assembly consists of three separate housings: - HVAC housing - The HVAC housing (1) is mounted to the dash panel behind the instrument panel and contains the A/C evaporator. The HVAC housing consists of an upper and a lower housing that are attached together and has mounting provisions for the air inlet housing, blower motor and the air distribution housing. - Air distribution housing - The air distribution housing (2) is mounted to the rear of the HVAC housing and contains the heater core, blend-air and mode-air doors and door linkage. - Air inlet housing - The air inlet housing (3) is mounted to the passenger side end of the HVAC housing. The air inlet housing contains the recirculation-air door and actuator when equipped with A/C. The heating-A/C system is a blend-air type system. The blend-air door controls the amount of conditioned air that is allowed to flow through, or around, the heater core. The A/C system is designed for the use of a non-CFC, R-134a refrigerant and uses an A/C evaporator to cool and dehumidify the incoming air prior to blending it with the heated air. A temperature control determines the discharge air temperature by operating the temperature control cable, which moves the blend-air door. This allows an almost immediate control of the output air temperature of the system. The mode door cable operates the mode-air doors which direct the flow of the conditioned air out the various air outlets, depending on the mode selected. When equipped with A/C, the recirculation door actuator operates the recirculation-air door which closes off the fresh air intake and recirculates the air already inside the vehicle. The electric recirculation door actuator and the blower motor are connected to the vehicle electrical system by the instrument panel wire harness. The blower motor controls the velocity of air flowing through the HVAC housing assembly by spinning the blower wheel within the HVAC housing at the selected speed by use of the blower motor resistor, which is located in the dash panel in the engine compartment. The air distribution housing must be removed from the HVAC housing and disassembled for service of the blend-air and mode-air doors. The air inlet housing must be removed from HVAC housing and disassembled for service of the recirculation-air door. The HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement Housing Assembly HVAC: Removal and Replacement Air Distribution Housing Removal HOUSING-AIR DISTRIBUTION WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death. NOTE: The air distribution housing must be removed from the HVAC housing and disassembled for service of the blend-air and mode-air doors. NOTE: LHD model with A/C shown in illustrations. RHD and heater-only models similar. 1. Remove the HVAC housing assembly and place it on a workbench. 2. Remove all of the floor distribution ducts from the air distribution housing (5). NOTE: If the foam seal for the flange is deformed or damaged, it must be replaced. 3. Remove the foam seal (1) from the flange (2) located on the front of the HVAC housing (9). 4. Remove the screw (10) that secures the flange to the front of the HVAC housing and remove the flange. 5. Remove the screw (3) that secures the retaining bracket (4) for the heater core tubes (8) to the left side of the air distribution housing. 6. On RHD models, remove the air distribution housing from the HVAC housing. 7. Carefully pull the heater core (6) out of the driver side of the air distribution housing. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7479 NOTE: Illustration shown with heater core and tubes removed from view for clarity. 8. Remove the two metal retaining clips (3) that secure the bottom of air distribution housing (2) to the HVAC housing (4). 9. Remove the seven screws (1) that secure the air distribution housing to the rear of the HVAC housing. 10. Remove the air distribution housing from the rear of the HVAC housing. 11. If required, disassemble the air distribution housing. Air Distribution Housing Installation HOUSING-AIR DISTRIBUTION NOTE: LHD model with A/C shown in illustrations. RHD and heater-only models similar. NOTE: Illustration shown with heater core and tubes removed from view for clarity. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7480 1. Position the air distribution housing (2) onto the rear of the HVAC housing (4). 2. Install the two metal retaining clips (3) that secure the bottom of the air distribution housing to the HVAC housing. 3. Install the seven screws (1) that secure the air distribution housing to the HVAC housing. Tighten the screws to 1.2 Nm (10 in. lbs.). 4. Carefully install the heater core (6) into the left side of the air distribution housing (5). 5. On RHD models, install the air distribution housing onto the HVAC housing (9). 6. Install the retaining bracket (4) and screw (3) that secure the heater core tubes (8). Tighten the screw to 1.2 Nm (10 in. lbs.) 7. Install the flange (2) that secures the heater core tubes to the front of the HVAC housing. 8. Install the screw (10) that secures the flange to the HVAC housing. Tighten the screw to 1.2 Nm (10 in. lbs.). NOTE: If the foam seal for the flange is deformed or damaged, it must be replaced. 9. Install the foam seal (1) onto the flange. 10. Install all of the floor distribution ducts onto the air distribution housing. NOTE: If the heater core is being replaced, flush the cooling system. 11. Install the HVAC housing assembly. Air Inlet Housing Removal HOUSING-AIR INLET WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death. NOTE: The air inlet housing must be removed from HVAC housing and disassembled for service of the recirculation-air door. NOTE: LHD model shown. RHD model similar. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7481 1. Remove the HVAC housing assembly and place it on a workbench. 2. If equipped, remove the particulate air filter. 3. Remove the four screws (1) that secure the air inlet housing (2) to the top of the HVAC housing (3). 4. Disengage the two plastic retaining tabs (4) that secure the air inlet housing to the HVAC housing and remove the inlet housing from the HVAC housing. 5. If required, disassemble the air inlet housing. Air Inlet Housing Installation HOUSING-AIR INLET NOTE: LHD model shown. RHD model similar. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7482 1. Install the air inlet housing (2) onto the top of the HVAC housing (3) and engage the two plastic retaining tabs (4). Make sure the retaining tabs are fully engaged. 2. Install the four screws (1) that secure the air inlet housing to the HVAC housing. Tighten the screws to 1.2 Nm (10 in. lbs.). 3. If equipped, install the particulate air filter. 4. Install the HVAC housing assembly. HVAC Housing - Removal HOUSING-HVAC WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in an accidental airbag deployment and possible personal injury or death. WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death. NOTE: The HVAC housing must be removed from the vehicle and disassembled for service of the heater core, A/C evaporator, air intake housing and the mode-air and blend-air doors. NOTE: LHD model shown in illustrations. RHD model similar. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant system. 3. Partially drain the engine cooling system. 4. Remove the three nuts (1) that secure the heat shield (3) to the studs (2) located on the dash panel in the engine compartment and remove the heat shield. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7483 5. Remove the bolt (1) that secures the A/C liquid and suction line assembly (2) to the A/C evaporator (3). 6. Disconnect the A/C liquid and suction line assembly from the A/C evaporator and remove and discard the dual-plane seals. 7. Install plugs in, or tape over the opened refrigerant line fittings and the evaporator ports. 8. Disconnect the heater hoses (4) from the heater core tubes. Install plugs in, or tape over the opened heater core tubes to prevent coolant spillage during housing removal. NOTE: Make sure to remove the five bolts that secure the HVAC housing to the instrument panel support prior to removing the instrument panel from the vehicle. 9. Remove the instrument panel. 10. Remove the rear floor ducts. 11. Remove the condensation drain tube. 12. Remove the nut (1) that secures the passenger side of the HVAC housing (2) to the dash panel (3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7484 NOTE: Use care to ensure that the interior is covered in case of loss of residual fluids from the heater and evaporator cores. 13. Pull the HVAC housing rearward and remove the HVAC housing assembly from the passenger compartment. HVAC Housing - Installation HOUSING - HVAC NOTE: LHD model shown in illustrations. RHD model similar. 1. Position the HVAC housing assembly (2) to the dash panel (3). Be certain that the passenger side of the HVAC housing is correctly located over the dash panel mounting stud. 2. Install the nut (1) that secures the HVAC housing to the passenger compartment side of dash panel. Tighten the nut to 4.5 Nm (40 in. lbs.). 3. Install the condensation drain tube. 4. Install the rear floor ducts. 5. Install the instrument panel. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7485 6. Remove the previously installed plugs or caps and connect the heater hoses (4) to the heater core tubes. 7. Remove the tape or plugs from the refrigerant line fittings and the evaporator ports. 8. Lubricate the rubber O-rings on new dual-plane seals with clean refrigerant oil and install the seals onto the liquid and suction line fittings. Use only the specified seals as they are made of special materials compatible to the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 9. Connect the A/C liquid and suction line assembly (2) to the A/C evaporator (3). 10. Install the bolt (1) that secures the A/C liquid and suction line assembly to the A/C evaporator. Tighten the bolt to 12 Nm (105 in. lbs.). 11. Position the heat shield (3) onto the studs (2) located on the dash panel in the engine compartment. 12. Install the three nuts (1) that secure the heat shield to the dash panel. Tighten the nuts to 1 Nm (10 in. lbs.). 13. Reconnect the negative battery cable. 14. If the heater core is being replaced, flush the cooling system. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7486 15. Refill the engine cooling system. 16. Evacuate the refrigerant system. 17. Charge the refrigerant system. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7487 Housing Assembly HVAC: Overhaul Air Distribution Housing HOUSING-AIR DISTRIBUTION NOTE: The air distribution housing must be removed from the HVAC housing and disassembled for service of the blend-air and mode-air doors. NOTE: LHD model with A/C shown in illustrations. RHD and heater-only models similar. 1. Remove the HVAC housing assembly and place it on a workbench. 2. Remove the air distribution housing (2) from the HVAC housing (1). 3. If equipped with the 2.0L diesel engine, remove the electric positive temperature coefficient (PTC) heater unit from the air distribution housing. 4. Remove the heater core from the air distribution housing. 5. Remove the temperature control cable (1) from the left side of the air distribution housing (2). 6. Remove the screw and washer (5) that secures the blend door cable lever (6) to the air distribution housing and remove the cable lever. NOTE: To remove the blend door pivot lever, disengage the retaining tab and pull the lever straight out of the air distribution housing. 7. Remove the blend door pivot lever (3) from the end of the blend door pivot shaft (4) and remove the pivot lever. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7488 8. Remove the mode door cable (1) from the right side of the air distribution housing (2). 9. Remove the screw and washer (3) that secure the mode door cam (4) to the air distribution housing and remove the cam. NOTE: If any foam seal on the air distribution housing outlets is deformed or damaged, the seal must be replaced. 10. Carefully cut the two foam seals (1) along the parting line (2) of the two halves of the air distribution housing (3). If either seal is deformed or damaged, it must be replaced. 11. Remove the five screws (4) and one metal clip (5) that secure the two halves of the air distribution housing together. 12. Disengage the three plastic retaining tabs (6) that secure the two halves of the air distribution housing together and carefully separate the housing. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7489 NOTE: If a seal on an air door is deformed or damaged, the air door must be replaced. 13. Disengage the air door(s) (1, 2, 3 and 4) from the mode door levers and remove the air doors from the air distribution housing (5). NOTE: To remove the mode door levers, disengage the retaining tabs on the inside of the air distribution housing and pull the levers straight out of the housing. 14. Remove the four mode door levers (1, 2, 3 and 4) from the right side of the air distribution housing (5). Air Inlet Housing HOUSING-AIR INLET NOTE: The air inlet housing must be removed from HVAC housing and disassembled for service of the recirculation-air door. NOTE: LHD model with A/C shown in illustrations. RHD and heater-only models similar. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7490 1. Remove the HVAC housing assembly and place it on a workbench. 2. Remove the air inlet housing (3) from the HVAC housing (1). 3. Remove the two screws (1) that secure the recirculation door actuator (2) to the right side of the air inlet housing (3) and remove the actuator. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7491 4. To remove the recirculation door pivot shaft adapter from the right end of the recirculation-air door, first carefully push down on the tab of the door lever pivot shaft adapter located inside of the air inlet housing, then pull the pivot shaft adapter straight out of the end of the recirculation-air door pivot shaft. NOTE: If the foam seal on the air inlet housing is deformed or damaged, the seal must be replaced. NOTE: If a rubber seal on the recirculation air-door is deformed or damaged, the air-door must be replaced. 5. Carefully pinch the two ends of the recirculation air-door together and remove the air-door from the air inlet housing. If the seal on the recirculation air-door is deformed or damaged, the air-door must be replaced. HVAC Housing HOUSING-HVAC NOTE: The HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator. NOTE: LHD model with A/C shown in illustrations. RHD and heater-only models similar. 1. Remove the HVAC housing assembly and place it on a workbench. 2. Remove the air distribution housing (2) from the HVAC housing (1). 3. Remove the air inlet housing (3) from the HVAC housing. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7492 4. Remove the three screws (1) that secure the wire lead bracket (2) and the blower motor (3) to the bottom of the HVAC housing (4) and remove the blower motor and wire lead bracket. 5. Remove the two screws (5) that secure the blower motor resistor (6) to the bottom of the HVAC housing and remove the resistor. 6. Using needle nose pliers (1), disengage the two retaining tabs (2) that secure the evaporator temperature sensor (3) to the driver side of the HVAC housing (4) and remove the sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7493 NOTE: If the foam seal for the flange is deformed or damaged, it must be replaced. 7. Carefully remove the foam seal (2) from the front of the two halves of the HVAC housing (4). If the seal is deformed or damaged, it must be replaced. 8. Remove the nine screws (3) and three metal clips (5) that secure the two halves of the HVAC housing together. 9. Disengage the nine plastic retaining tabs (1) that secure the two halves of the HVAC housing together and separate the housing. NOTE: If the foam insulator around the A/C evaporator is deformed or damaged, the insulator must be replaced. 10. Carefully lift the A/C evaporator (1) and the foam insulator (2) out of the lower half of the HVAC housing (3). NOTE: If the seal around the evaporator tube tapping block is deformed or damaged, the seal must be replaced. 11. If required, remove the seal (4) from around the evaporator tube tapping block (5). Air Distribution Housing Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7494 HOUSING-AIR DISTRIBUTION NOTE: LHD model with A/C shown in illustrations. RHD and heater-only models similar. 1. Install the four mode door levers (1, 2, 3 and 4) onto the right side of the air distribution housing (5) Make sure the lever retaining tabs are fully engaged to the housing. NOTE: Properly position the air doors within the air distribution housing by first aligning the four mode door levers to the scribe lines located on the right outer side of the air distribution housing. Then, install the air doors onto the mode door levers with the UP mark on each air door facing toward the top of the housing. NOTE: If a seal on an air door is deformed or damaged, the air door must be replaced. 2. Align the four mode door levers to the scribe lines on the right outer side of the air distribution housing (5) and install the air door(s) (1, 2, 3 and 4) onto the mode door levers with the UP mark on each air door facing toward the top of the housing. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7495 3. Align the air door(s) with the pivot shaft hole(s) in the air distribution housing (3) and install the two halves of the housing together. Make sure the three plastic retaining tabs (6) are fully engaged. 4. Install the five screws (4) and one metal clip (5) that secure the two halves of the air distribution housing together. Tighten the screws to 2.2 Nm (20 in lbs.). Make sure the metal clip is fully engaged to the housing halves. NOTE: If any foam seal on the air distribution housing outlets is deformed or damaged, the seal must be replaced. 5. Inspect the foam seals (1), especially at the parting line (2). If a foam seal is deformed or damaged, it must be replaced. NOTE: Align the pins on the mode door levers with the grooves in the back of the mode door cam prior to installation of the cam. 6. Align the mode door levers on the right side of the air distribution housing (2) to the mode door cam (4) and install the cam onto the housing. Make sure the levers are correctly engaged to the cam. 7. Install the screw and washer (3) that secure the mode door cam to the air distribution housing. Tighten the screw to 0.6 Nm (5 in. lbs.). 8. Install the mode door cable (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7496 9. Install the blend door pivot lever (3) onto the end of the blend door pivot shaft (4) located on the left side of the air distribution housing (2). Make sure the lever retaining tab is fully engaged to the pivot shaft. NOTE: Align the pin on the blend door lever with the groove in the pivot lever prior to installation of the blend door lever. 10. Install the blend door lever (6) onto the air distribution housing. Make sure the levers are correctly aligned to each other. 11. Install the screw and washer (5) that secure the blend door lever to the air distribution housing. Tighten the screw to 0.6 Nm (5 in. lbs.). 12. Install the temperature control cable (1). 13. If equipped with the 2.0L diesel engine, install the electric positive temperature coefficient (PTC) heater unit into the air distribution housing. 14. Install the heater core into the air distribution housing (2). 15. Install the air distribution housing onto the HVAC housing (1). 16. Install the HVAC housing assembly. Air Inlet Housing HOUSING-AIR INLET NOTE: LHD model with A/C shown in illustrations. RHD and heater-only models similar. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7497 1. Carefully install the recirculation-air door (1) into the air inlet housing (2) by pinching the two ends of the air-door together and aligning the pivot shafts of the air-door to the pivot shaft holes in the air inlet housing. NOTE: Install the recirculation door pivot shaft adapter by carefully pushing it straight into the end of the recirculation door pivot shaft. 2. Install the recirculation door pivot shaft adapter (3) into the right side pivot shaft of the recirculation air-door. Make sure the adapter is fully engaged to the pivot shaft. 3. Install the recirculation door actuator (1) onto the right side of the air inlet housing (2). If necessary, rotate the actuator slightly to align the splines of the actuator output shaft (3) with those on the recirculation door pivot shaft adapter (4). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7498 4. Install the air inlet housing (3) onto the HVAC housing (1). 5. Install the HVAC housing assembly. HVAC Housing HOUSING-HVAC NOTE: LHD model with A/C shown in illustrations. RHD and heater-only models similar. 1. If removed, install the seal (4) onto the evaporator tube tapping block (5). NOTE: Make sure that the foam insulator is properly positioned in the HVAC housing. 2. Carefully install the A/C evaporator (1) and foam insulator (2) into the lower half of the HVAC housing (3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7499 3. Install the two halves of the HVAC housing (4) together and engage the nine plastic retaining tabs (1). Make sure the retaining tabs are fully engaged. 4. Install the nine screws (3) and three metal clips (5) that secure the two halves of the HVAC housing together. Tighten the screws to 1.2 Nm (10 in lbs.). Make sure the metal clips are fully engaged to the housing halves. 5. Install the foam seal (2) onto the front of the two HVAC housing halves. 6. Install the evaporator temperature sensor (1) into the driver side of the HVAC housing (2). Make sure the retaining tabs (3) are fully engaged to the housing. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7500 7. Position the blower motor (3) into the bottom of the HVAC housing (4). 8. Install the wire lead bracket (2) and the three screws (1) that secure the blower motor to the HVAC housing. Tighten the screws to 1.2 Nm (10 in. lbs.). 9. Position the blower motor resistor (6) into the HVAC housing. 10. Install the two screws (5) that secure the blower motor resistor to the HVAC housing. Tighten the screws to 1.2 Nm (10 in. lbs.). 11. Install the air inlet housing (3) onto the HVAC housing (1). 12. Install the air distribution housing (2) onto the HVAC housing. NOTE: If the heater core is being replaced, flush the cooling system. 13. Install the HVAC housing assembly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications Refrigerant: Specifications Refrigerant Charge Capacity Single Unit ........................................................................................................................................... ..................................................... 0.51kg (1.125 lbs) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Description and Operation > Description Refrigerant: Description and Operation Description DESCRIPTION The refrigerant used in this air conditioning system is a Hydro Fluoro Carbon (HFC), type R-134a. Unlike R-12, which is a Chloro Fluoro Carbon (CFC), R-134a refrigerant does not contain ozone-depleting chlorine. R-134a refrigerant is a non-toxic, non-flammable, clear, and colorless liquefied gas. Even though R-134a does not contain chlorine, it must be reclaimed and recycled just like CFC-type refrigerants. This is because R-134a is a greenhouse gas and can contribute to global warming. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Description and Operation > Description > Page 7506 Refrigerant: Description and Operation Operation OPERATION R-134a refrigerant is not compatible with R-12 refrigerant in an A/C system. Even a small amount of R-12 refrigerant added to an R-134a refrigerant system will cause A/C compressor failure, refrigerant oil sludge or poor A/C system performance. In addition, the polyalkylene glycol (PAG) synthetic refrigerant oils used in an R-134a refrigerant system are not compatible with the mineral-based refrigerant oils used in an R-12 refrigerant system. R-134a refrigerant system service ports, service tool couplers and refrigerant dispensing bottles have all been designed with unique fittings to ensure that an R-134a refrigerant system is not accidentally contaminated with the wrong refrigerant (R-12). There are also labels posted in the engine compartment of the vehicle and on the A/C compressor to identify that the A/C system is equipped with R-134a refrigerant. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Description and Operation > Page 7507 Refrigerant: Testing and Inspection REFRIGERANT SYSTEM LEAKS WARNING: R-134a service equipment or vehicle A/C system should not be pressure tested or leak tested with compressed air. Mixture of air and R-134a can be combustible at elevated pressures. These mixtures are potentially dangerous and may result in fire or explosion causing property damage, personal injury or death. Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Use only approved service equipment meeting SAE requirements to discharge an R-134a system. If accidental system discharge occurs, ventilate work area before resuming service. NOTE: If the A/C refrigerant system charge is empty or low, a leak in the A/C system is likely. Visually inspect all A/C lines, fittings and components for an oily residue. Oil residue can be an indicator of an A/C system leak location. NOTE: The only way to correctly determine if the refrigerant system is fully charged with R-134a is to completely evacuate and recharge the A/C system. Connect a suitable manifold gauge set and determine if the static A/C system pressure is above or below 345 kPa (50 psi). If less than 345 kPa (50 psi) , proceed to SYSTEM EMPTY. If greater than 345 kPa (50 psi), go to SYSTEM LOW. SYSTEM EMPTY 1. Evacuate the refrigerant system to the lowest degree of vacuum possible (approximately -88 kPa (-26 in. Hg) or greater vacuum). Determine if the system holds a vacuum for 15 minutes. If vacuum is held, a leak is probably not present. If system will not maintain vacuum level, proceed to STEP 2. 2. Prepare and dispense 0.284 kilograms (10 ounces) of R-134a refrigerant into the evacuated refrigerant system and proceed to STEP 1 of the System Low procedure. SYSTEM LOW 3. Position the vehicle in a wind-free work area. This will aid in detecting small leaks. 4. Operate the heating-A/C system with the engine at idle under the following conditions for at least 5 minutes. - Doors or windows open - Transaxle in Park or Neutral with the parking brake set (depending on application) - A/C-heater controls set to outside air, full cool, panel mode, high blower and with A/C compressor engaged CAUTION: A leak detector only designed for R-12 refrigerant will not detect leaks in an R-134a refrigerant system. 5. Shut the vehicle Off and wait 2-7 minutes. Then use an electronic leak detector that is designed to detect R-134a refrigerant and search for leaks. Fittings, lines or components that appear to be oily usually indicate a refrigerant leak. To inspect the A/C evaporator for leaks, insert the leak detector probe into the drain tube opening or an air outlet. A dye for R-134a is available to aid in leak detection. Use only DaimlerChrysler approved refrigerant dye. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Refrigerant System Recovery Refrigerant: Service and Repair Refrigerant System Recovery REFRIGERANT SYSTEM RECOVERY WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions may result in serious or fatal injury. An R-134a refrigerant recovery/recycling/charging station (1) that meets SAE standard J2210 must be used to recover the refrigerant from the R-134a refrigerant system. Refer to the operating instructions supplied by the equipment manufacturer for the proper care and use of this equipment. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Refrigerant System Recovery > Page 7510 Refrigerant: Service and Repair Refrigerant System Evacuate REFRIGERANT SYSTEM EVACUATE CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system. Failure to follow this caution will result in serious A/C compressor damage. NOTE: Special effort must be used to prevent moisture from entering the A/C system oil. Moisture in the oil is very difficult to remove and will cause a reliability problem with the A/C compressor. If an A/C compressor designed to use R-134a refrigerant is left open to the atmosphere for an extended period of time. It is recommended that the refrigerant oil be drained and replaced with new oil or a new A/C compressor be used. This will eliminate the possibility of contaminating the refrigerant system. If the refrigerant system has been open to the atmosphere, it must be evacuated before the system can be filled. Moisture and air mixed with the refrigerant will raise the compressor head pressure above acceptable operating levels. This will reduce the performance of the A/C system and damage the A/C compressor. Moisture will boil at near room temperature when exposed to vacuum. To evacuate the refrigerant system: NOTE: When connecting the service equipment coupling to the line fitting, verify that the valve of the coupling is fully closed. This will reduce the amount of effort required to make the connection. 1. Recover the refrigerant system. 2. With the engine OFF, connect a suitable charging station, refrigerant recovery machine or a manifold gauge set with vacuum pump and refrigerant recovery equipment. Do not operate the engine with a vacuum on the A/C system. 3. Open the suction and discharge valves and start the vacuum pump. The vacuum pump should run a minimum of 45 minutes prior to charge to eliminate all moisture in system. When the suction gauge reads to the lowest degree of vacuum possible (approximately -88 kPa (- 26 in. Hg) or greater) for 30 minutes, close all valves and turn off vacuum pump. If the system fails to reach specified vacuum, the refrigerant system likely has a leak that must be corrected. If the refrigerant system maintains specified vacuum for at least 30 minutes, start the vacuum pump, open the suction and discharge valves. Then allow the system to evacuate an additional 10 minutes. 4. Close all valves. Turn off and disconnect the vacuum pump. 5. Charge the refrigerant system. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Refrigerant System Recovery > Page 7511 Refrigerant: Service and Repair Refrigerant System Charge REFRIGERANT SYSTEM CHARGE WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death. NOTE: The Underhood HVAC Specification Label contains the refrigerant fill specification of the vehicle being serviced. After all refrigerant system leaks have been repaired and the refrigerant system has been evacuated, a refrigerant charge can be injected into the system. An R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 must be used to charge the refrigerant system with R-134a refrigerant. Refer to the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment. CHARGING PROCEDURE CAUTION: A small amount of refrigerant oil is removed from the A/C system each time the refrigerant system is recovered and evacuated. Before charging the A/C system, you MUST replenish any oil lost during the recovery process. 1. Evacuate the refrigerant system. 2. A manifold gauge set and an R-134a refrigerant recovery/recycling/charging station that meets SAE standard J2210 should be connected to the refrigerant system. 3. Measure the proper amount of refrigerant and heat it to 52° C (125° F) with the charging station. See the operating instructions supplied by the equipment manufacturer for proper use of this equipment. 4. Open both the suction and discharge valves, then open the charge valve to allow the heated refrigerant to flow into the system. 5. When the transfer of refrigerant has stopped, close both the suction and discharge valves. 6. If all of the refrigerant charge did not transfer from the dispensing device, open all of the windows in the vehicle and set the heating-A/C system controls so that the A/C compressor is operating and the blower motor is running at its lowest speed setting. Run the engine at a steady high idle (about 1400 rpm). 7. Open the low-side valve to allow the remaining refrigerant to transfer to the refrigerant system. WARNING: Take care not to open the discharge (high pressure) valve at this time. Failure to follow this warning could result in possible personal injury or death. 8. Disconnect the charging station and manifold gauge set from the refrigerant system service ports. 9. Reinstall the caps onto the refrigerant system service ports. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Page 7512 Refrigerant: Tools and Equipment REFRIGERANT SYSTEM SERVICE EQUIPMENT WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death. WARNING: Eye protection must be worn when servicing an air conditioning refrigerant system. Turn off (rotate clockwise) all valves on the equipment being used, before connecting to or disconnecting from the refrigerant system. Failure to observe these warnings may result in personal injury or death. When servicing the A/C system, an R-134a refrigerant recovery/recycling/charging station that meets SAE standard J2210 must be used (1). Contact an automotive service equipment supplier for refrigerant recovery/recycling/charging equipment. Refer to the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment. A manifold gauge set (1) may be needed with some recovery/recycling/charging equipment. The manifold gauge set should have manual shut-off valves (2 and 6), or automatic back-flow valves located at the service port connector end of the manifold gauge set hoses (4 and 5). This will prevent refrigerant Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Page 7513 from being released into the atmosphere. MANIFOLD GAUGE SET CONNECTIONS CAUTION: Do not use an R-12 manifold gauge set on an R-134a system. The refrigerants are not compatible and system damage will result. - LOW PRESSURE GAUGE HOSE - The low pressure hose (Blue with Black stripe) attaches to the low side service port. This port is located on the A/C liquid line near the right front strut tower. - HIGH PRESSURE GAUGE HOSE - The high pressure hose (Red with Black stripe) attaches to the high side service port. This port is located on the A/C discharge line near the A/C condenser. - RECOVERY/RECYCLING/EVACUATION/CHARGING HOSE - The center manifold hose (Yellow, or White, with Black stripe) is used to recover, evacuate, and charge the refrigerant system. When the low or high pressure valves on the manifold gauge set are opened, the refrigerant in the system will escape through this hose. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Description and Operation > Description Refrigerant Oil: Description and Operation Description DESCRIPTION The refrigerant oil used in R-134a refrigerant systems is a synthetic-based, polyalkylene glycol (PAG), wax-free lubricant. Mineral-based R-12 refrigerant oils are not compatible with PAG oils and should never be introduced to an R-134a refrigerant system. There are different PAG oils available and each contain a different additive package. Always use only the type of refrigerant oil recommended for the A/C compressor in the vehicle. CAUTION: Be certain to adjust the refrigerant system oil level when replacing an A/C compressor. Failure to properly adjust the refrigerant oil level can prevent the A/C system from operating as designed and can cause serious A/C compressor damage. The Denso 5SE12C A/C compressor used in this vehicle is designed to use ND-8 PAG refrigerant oil. Use only this type of refrigerant oil in the refrigerant system. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Description and Operation > Description > Page 7519 Refrigerant Oil: Description and Operation Operation OPERATION After performing any refrigerant recovery or recycling operation, always replenish the refrigerant system with the same amount of the recommended refrigerant oil as was removed. Too little refrigerant oil can cause A/C compressor damage, and too much can reduce A/C system performance. PAG refrigerant oil is more hygroscopic than mineral oil, and will absorb any moisture it comes into contact with, even moisture in the air. The PAG oil container should always be kept tightly capped until it is ready to be used. After use, recap the oil container immediately to prevent moisture contamination. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Description and Operation > Page 7520 Refrigerant Oil: Service and Repair REFRIGERANT OIL LEVEL When an A/C system is assembled at the factory, all components except the A/C compressor are refrigerant oil free. After the refrigerant system has been charged and operated, the refrigerant oil in the A/C compressor is dispersed throughout the refrigerant system. The A/C accumulator, A/C evaporator, A/C condenser and the A/C compressor will each retain a significant amount of the needed refrigerant oil. It is important to have the correct amount of refrigerant oil in the A/C system. This ensures proper lubrication of the A/C compressor. Too little oil will result in damage to the A/C compressor, while too much oil will reduce the cooling capacity of the A/C system and consequently result in higher discharge air temperatures. CAUTION: ND-8 PAG refrigerant oil is used in the Denso 5SE12C A/C compressor. Only refrigerant oil of the same type should be used to service this R-134a A/C system. Do not use any other refrigerant oil. The refrigerant oil container should be kept tightly capped until it is ready for use and then tightly capped after use to prevent contamination from moisture and dirt. Refrigerant oil will quickly absorb any moisture it comes in contact with, therefore, special effort must be used to keep all R-134a system components moisture-free. Moisture in the refrigerant oil is very difficult to remove and will cause a reliability problem with the A/C compressor. NOTE: Most reclaim/recycling equipment will measure the amount of refrigerant oil being removed during the recovery process. This amount of refrigerant oil should always be added back into the refrigerant system. It will not be necessary to check the oil level within the A/C refrigerant system or to add oil, unless there has been an oil loss. A refrigerant oil loss may occur due to component replacement or a rupture or leak from a refrigerant line, connector fitting, component or component seal. If a leak does occurs, add 30 milliliters (1 fluid ounce) of the recommended refrigerant oil to the refrigerant system after the repair has been made. Refrigerant oil loss will be evident at the leak point by the presence of a wet, shiny surface around the leak. Refrigerant oil must be added when an A/C accumulator, A/C evaporator or A/C condenser is replaced. Refer to the Refrigerant Oil Capacities chart. The refrigerant oil level in a new A/C compressor must first be adjusted prior to compressor installation. Refer to the following COMPRESSOR OIL DRAIN PROCEDURE. COMPRESSOR OIL DRAIN PROCEDURE CAUTION: Be certain to adjust the refrigerant system oil level when replacing an A/C compressor. The refrigerant oil in the Denso 5SE12C A/C compressor can only be drained using the procedure described below. Failure to properly drain the refrigerant oil from the A/C compressor can prevent the A/C system from operating as designed and cause serious compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be removed from the new A/C compressor (example: new compressor and accumulator requires 80 ml. (2.7 oz.) of oil to be added to the system. 120 ml. (4.1 oz.) of oil is in new compressor. 120 ml. (4.1 oz.) minus 80 ml. (2.7 oz.) equals 40 ml. (1.4 oz.) oil to be drained from new compressor). The Denso 5SE12C A/C compressor is filled with 120 milliliters (4.1 oz.) from the factory. When only the A/C compressor is being replaced, 70 milliliters (2.4 oz.) of refrigerant oil must first be drained from the new compressor prior to installation. Use the following procedure to drain and measure refrigerant oil from the Denso 5SE12C A/C compressor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Description and Operation > Page 7521 1. Place the new A/C compressor (1) on a workbench, 2. Position the A/C compressor so that the refrigerant oil can drain out of the suction port (2) into a suitable clean measured container. Hold the A/C compressor in this position until no more oil comes out of the compressor port. 3. Reposition the A/C compressor (1) so that the pulley (2) is facing upward and slowly rotate the compressor pulley clockwise one full turn. 4. Repeat steps 2 and 3 at least seven times or until 70 milliliters (2.4 oz.) of refrigerant oil is drained from the new A/C compressor. CAUTION: Failure to properly adjust the refrigerant oil level prior to installation of a new compressor can prevent the A/C system from operating as designed and cause serious compressor damage. 5. Install the new A/C compressor onto the engine. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Refrigerant Pressure Sensor / Switch: Locations Component ID: 360 Component : TRANSDUCER-A/C PRESSURE Connector: Name : TRANSDUCER-A/C PRESSURE Color : GRAY # of pins : 4 Pin Description Circuit 1 A/C PRESSURE SENSOR GROUND C918 20BK/LB 2 A/C PRESSURE SENSOR SUPPLY C818 20LB/TN 3 A/C PRESSURE SENSOR SIGNAL C18 20LB/BR 4-Component Location - 4 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7525 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7526 Refrigerant Pressure Sensor / Switch: Diagrams Component ID: 360 Component : TRANSDUCER-A/C PRESSURE Connector: Name : TRANSDUCER-A/C PRESSURE Color : GRAY # of pins : 4 Pin Description Circuit 1 A/C PRESSURE SENSOR GROUND C918 20BK/LB 2 A/C PRESSURE SENSOR SUPPLY C818 20LB/TN 3 A/C PRESSURE SENSOR SIGNAL C18 20LB/BR 4-Component Location - 4 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7527 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Description Refrigerant Pressure Sensor / Switch: Description and Operation Description DESCRIPTION The A/C pressure transducer (1) is a switch that is installed on a fitting located on the A/C discharge line. An internally threaded fitting on the A/C pressure transducer connects it to the externally threaded Schrader-type fitting on the A/C discharge line. A rubber O-ring seals the connection between the A/C pressure transducer and the discharge line fitting. The A/C pressure transducer is connected to the vehicle electrical system by a molded plastic connector with three terminals. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Description > Page 7530 Refrigerant Pressure Sensor / Switch: Description and Operation Operation OPERATION The A/C pressure transducer monitors the pressures in the high side of the refrigerant system through its connection to a fitting on the A/C discharge line. The internal resistance of the A/C pressure transducer changes in response to the pressures it monitors. The totally integrated power module (TIPM) provides a five volt reference signal and a sensor ground to the A/C pressure transducer. The TIPM then monitors the output voltage of the transducer on a sensor return circuit to determine refrigerant pressure and sends a message to the powertrain control module (PCM) or the engine control module (ECM) (depending on engine application) over the CAN C BUS. The PCM/ECM is programmed to respond to this and other sensor inputs by controlling the operation of the swashplate within the A/C compressor and the radiator cooling fan to help optimize A/C system performance and to protect the system components from damage. The PCM adjusts the swashplate to nearly a zero degree angle (low compressor displacement) when high side pressure rises above 3130 kPa (454 psi) and re-adjusts the swashplate to a greater angle (higher compressor displacement) when high side pressure drops below 1999 kPa (290 psi). The A/C pressure transducer also reduces the swashplate angle if the high side pressure drops below 200 kPa (29 psi) and will increase the swashplate angle when the high side pressure rises above 234 262 kPa (34 - 38 psi). When the refrigerant pressure rises above 1655 kPa (240 psi), the PCM will actuate the cooling fan. A Schrader-type valve in the A/C discharge line fitting permits the A/C pressure transducer to be removed or installed without disturbing the refrigerant in the A/C system. The A/C pressure transducer is diagnosed using a scan tool. The A/C pressure transducer cannot be adjusted or repaired and must be replaced if found inoperative or damaged. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Removal Refrigerant Pressure Sensor / Switch: Service and Repair Removal REMOVAL NOTE: It is not necessary to discharge the refrigerant system to replace the A/C pressure transducer. NOTE: Typical A/C pressure transducer shown. 1. Disconnect and isolate the negative battery cable. 2. Carefully pull the top of the fascia forward to gain access to the A/C pressure transducer (2). 3. Reach down through the opening between the A/C condenser and the front fascia and disconnect the wire harness connector (1) from the A/C pressure transducer located on the A/C discharge line (3). 4. Remove the A/C pressure transducer from the fitting on the A/C discharge line and remove and discard the O-ring seal. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Removal > Page 7533 Refrigerant Pressure Sensor / Switch: Service and Repair Installation INSTALLATION NOTE: Use only the specified O-ring as it is made of special material for R-134a. Use only refrigerant oil of the type required for the A/C compressor. NOTE: Typical A/C pressure transducer shown. 1. Lubricate a new rubber O-ring seal (4) with clean refrigerant oil and install it onto the discharge line fitting (3). 2. Install the A/C pressure transducer (2) onto the A/C discharge line. Tighten the A/C pressure transducer securely. 3. Connect the wire harness connector (1) to the A/C pressure transducer. 4. Reinstall the top of the front fascia. 5. Reconnect the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerator > Component Information > Technical Service Bulletins > Customer Interest for Refrigerator: > 24-005-07 > Jul > 07 > Accessories - Chill Zone Won't Stay Cold Refrigerator: Customer Interest Accessories - Chill Zone Won't Stay Cold NUMBER: 24-005-07 GROUP: Heating & Air Conditioning DATE: July 19,2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-005-06 REV. A, DATED SEPTEMBER 14, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES 2008 MODELS AND REMOVAL OF CLEAN POINTS. SUBJECT: Chill Zone Does Not Stay Cold Or Mode Door Does Not Stay In Position OVERVIEW: This bulletin involves applying a piece of sticky back foam tape to the chill zone mode door. NOTE: For detailed Chill Zone operating information consult the Owner Manual. MODELS: **2007- (PM) Caliber 2008** SYMPTOM/CONDITION: The customer may describe that chill zone does not stay cold or that the chill zone mode door does not stay in position. DIAGNOSIS: If the vehicle exhibits the symptom/condition listed above perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. Open glove box. 3. Using trim stick (C-4755) remove the chill zone mode door. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerator > Component Information > Technical Service Bulletins > Customer Interest for Refrigerator: > 24-005-07 > Jul > 07 > Accessories - Chill Zone Won't Stay Cold > Page 7542 4. Apply a piece of sticky back open cell foam tape 10 mm (.39 inch) tall by 10 mm (.39 inch) wide by 50 mm (2 inch) long to the mode door facing upward. Position the tape as shown in (Fig 1). 5. Install the chill zone mode door. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerator > Component Information > Technical Service Bulletins > Customer Interest for Refrigerator: > 24-005-06A > Sep > 06 > Accessories - Chill Zone Does Not Stay Cold Refrigerator: Customer Interest Accessories - Chill Zone Does Not Stay Cold NUMBER: 24-005-06 REV. A GROUP: Heating & Air Conditioning DATE: September 14, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-005-06, DATED JUNE 14, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES A NEW VEHICLE BUILD DATE. SUBJECT: Chill Zone Does Not Stay Cold Or Chill Zone Mode Door Does Not Stay In Position OVERVIEW: This bulletin involves applying a piece of sticky back foam tape to the chill zone mode door. NOTE: For detail Chill Zone operating information consult the Owner Manual. MODELS: 2007 (PM) Caliber NOTE: **This bulletin applies to vehicles built on or before August 20, 2006 (MDH 0820XX).** SYMPTOM/CONDITION: The customer may describe that chill zone does not stay cold or that the chill zone mode door does not stay in position. DIAGNOSIS: If the vehicle exhibits the symptom/condition listed above perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. Open glove box. 3. Using trim stick (C-4755) remove the chill zone mode door. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerator > Component Information > Technical Service Bulletins > Customer Interest for Refrigerator: > 24-005-06A > Sep > 06 > Accessories - Chill Zone Does Not Stay Cold > Page 7547 4. Apply a piece of sticky back open cell foam tape 10 mm (.39 inch) tall by 10 mm (.39 inch) wide by 50 mm (2 inch) long to the mode door facing upward. Position the tape as shown in (Fig. 1). 5. Install the chill zone mode door. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerator: > 24-005-07 > Jul > 07 > Accessories - Chill Zone Won't Stay Cold Refrigerator: All Technical Service Bulletins Accessories - Chill Zone Won't Stay Cold NUMBER: 24-005-07 GROUP: Heating & Air Conditioning DATE: July 19,2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-005-06 REV. A, DATED SEPTEMBER 14, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES 2008 MODELS AND REMOVAL OF CLEAN POINTS. SUBJECT: Chill Zone Does Not Stay Cold Or Mode Door Does Not Stay In Position OVERVIEW: This bulletin involves applying a piece of sticky back foam tape to the chill zone mode door. NOTE: For detailed Chill Zone operating information consult the Owner Manual. MODELS: **2007- (PM) Caliber 2008** SYMPTOM/CONDITION: The customer may describe that chill zone does not stay cold or that the chill zone mode door does not stay in position. DIAGNOSIS: If the vehicle exhibits the symptom/condition listed above perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. Open glove box. 3. Using trim stick (C-4755) remove the chill zone mode door. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerator: > 24-005-07 > Jul > 07 > Accessories - Chill Zone Won't Stay Cold > Page 7553 4. Apply a piece of sticky back open cell foam tape 10 mm (.39 inch) tall by 10 mm (.39 inch) wide by 50 mm (2 inch) long to the mode door facing upward. Position the tape as shown in (Fig 1). 5. Install the chill zone mode door. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerator: > 24-005-06A > Sep > 06 > Accessories - Chill Zone Does Not Stay Cold Refrigerator: All Technical Service Bulletins Accessories - Chill Zone Does Not Stay Cold NUMBER: 24-005-06 REV. A GROUP: Heating & Air Conditioning DATE: September 14, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-005-06, DATED JUNE 14, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES A NEW VEHICLE BUILD DATE. SUBJECT: Chill Zone Does Not Stay Cold Or Chill Zone Mode Door Does Not Stay In Position OVERVIEW: This bulletin involves applying a piece of sticky back foam tape to the chill zone mode door. NOTE: For detail Chill Zone operating information consult the Owner Manual. MODELS: 2007 (PM) Caliber NOTE: **This bulletin applies to vehicles built on or before August 20, 2006 (MDH 0820XX).** SYMPTOM/CONDITION: The customer may describe that chill zone does not stay cold or that the chill zone mode door does not stay in position. DIAGNOSIS: If the vehicle exhibits the symptom/condition listed above perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. Open glove box. 3. Using trim stick (C-4755) remove the chill zone mode door. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerator: > 24-005-06A > Sep > 06 > Accessories - Chill Zone Does Not Stay Cold > Page 7558 4. Apply a piece of sticky back open cell foam tape 10 mm (.39 inch) tall by 10 mm (.39 inch) wide by 50 mm (2 inch) long to the mode door facing upward. Position the tape as shown in (Fig. 1). 5. Install the chill zone mode door. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Temperature Sensor / Switch HVAC: Locations Component ID: 282 Component : SENSOR-AMBIENT AIR TEMPERATURE Connector: Name : SENSOR-AMBIENT AIR TEMPERATURE Color : BLACK # of pins : 2 Pin Description Circuit 1 AAT SIGNAL G31 20VT/LG 2 AAT RETURN G931 20VT/DB Component Location - 10 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 7563 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 7564 Ambient Temperature Sensor / Switch HVAC: Diagrams Component ID: 282 Component : SENSOR-AMBIENT AIR TEMPERATURE Connector: Name : SENSOR-AMBIENT AIR TEMPERATURE Color : BLACK # of pins : 2 Pin Description Circuit 1 AAT SIGNAL G31 20VT/LG 2 AAT RETURN G931 20VT/DB Component Location - 10 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 7565 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation > Description Ambient Temperature Sensor / Switch HVAC: Description and Operation Description DESCRIPTION The ambient temperature sensor is a variable resistor type sensor. It is mounted to the lower front fascia behind the radiator grille and in front of the engine compartment. The ambient temperature sensor cannot be adjusted or repaired and, if inoperative or damaged, it must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation > Description > Page 7568 Ambient Temperature Sensor / Switch HVAC: Description and Operation Operation OPERATION The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal. The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the Totally Integrated Power Module (TIPM). Based upon the resistance in the sensor, the instrument cluster or Cab Compartment Node (CCN) display senses a specific voltage on the Controller Area Network (CAN) data bus circuit, which corresponds to a specific temperature. The compass/temperature display unit then displays the proper ambient temperature. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation > Page 7569 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection AMBIENT TEMPERATURE SENSOR The thermometer function is supported by the ambient temperature sensor, the Totally Integrated Power Module (TIPM), the Controller Area Network (CAN) data bus circuit, and the instrument cluster or Cab Compartment Node (CCN) compass/temperature display unit. If the display shows "O" (-45° C (-49° F)) or "SC" (60° C (140° F)), there is an OPEN or SHORT CIRCUIT that must be repaired. The ambient temperature sensor circuit can also be diagnosed using the following Sensor Test, and Sensor Circuit Test. If the temperature sensor and circuit are confirmed to be OK, but the temperature display is inoperative or incorrect, replace the instrument cluster or CCN assembly. SENSOR TESTING 1. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. 2. Disconnect the ambient temperature sensor wire harness connector. 3. Measure the resistance of the ambient temperature sensor. At room temperature (approx. 20° C (68° F)), the sensor resistance should be between 9-11 Kilohms (9000-11000 ohms). The sensor resistance should read between these two values. If OK, refer to the appropriate diagnostic information to continue diagnosis of the Totally Integrated Power Module (TIPM), the Controller Area Network (CAN) data bus circuit, and the instrument cluster or CCN. If not OK, replace the inoperative ambient temperature sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Service and Repair > Removal Ambient Temperature Sensor / Switch HVAC: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the belly pan. 3. Disconnect the wire harness connector (1) from the ambient temperature sensor (2). 4. Remove the fastener that secures the ambient temperature sensor bracket to the front fascia. 5. Remove the ambient temperature sensor from the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Service and Repair > Removal > Page 7572 Ambient Temperature Sensor / Switch HVAC: Service and Repair Installation INSTALLATION 1. Position the ambient temperature sensor in the vehicle. 2. Install the fastener that secures the ambient temperature sensor to the front fascia. 3. Connect the wire harness connector (1) to the ambient temperature sensor (2). 4. Install the belly pan. 5. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations Component ID: 292 Component : SENSOR-EVAPORATOR TEMPERATURE Connector: Name : SENSOR-EVAPORATOR TEMPERATURE Color : NATURAL # of pins : 2 Pin Description Circuit 1 EVAPORATOR TEMPERATURE SENSOR SIGNAL C21 20DB/LG 2 SENSOR GROUND C121 20DB/DG Component Location - 23 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 7576 Fig. 23 Component Location - 24 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 7577 Component Location - 26 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 7578 Component Location - 29 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 7579 Fig. 29 Component Location - 30 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 7580 Component Location - 32 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 7581 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 7582 Evaporator Temperature Sensor / Switch: Diagrams Component ID: 292 Component : SENSOR-EVAPORATOR TEMPERATURE Connector: Name : SENSOR-EVAPORATOR TEMPERATURE Color : NATURAL # of pins : 2 Pin Description Circuit 1 EVAPORATOR TEMPERATURE SENSOR SIGNAL C21 20DB/LG 2 SENSOR GROUND C121 20DB/DG Component Location - 23 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 7583 Fig. 23 Component Location - 24 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 7584 Component Location - 26 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 7585 Component Location - 29 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 7586 Fig. 29 Component Location - 30 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 7587 Component Location - 32 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 7588 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Description Evaporator Temperature Sensor / Switch: Description and Operation Description DESCRIPTION The evaporator temperature sensor measures the temperature of the conditioned air downstream of the A/C evaporator. The evaporator temperature sensor is an electrical thermistor (1) mounted on the end of a molded plastic housing (2) that is inserted into the driver side of the HVAC housing near the coldest point of the A/C evaporator. The evaporator temperature sensor is retained in the HVAC housing by two integral retaining tabs (3) and is connected to the vehicle electrical system by use of a wire lead and connector (4) with two terminals. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Description > Page 7591 Evaporator Temperature Sensor / Switch: Description and Operation Operation OPERATION The evaporator temperature sensor monitors the surface temperature of A/C evaporator and supplies an input signal to the A/C-heater control. The A/C-heater control uses the evaporator temperature sensor input signal to optimize A/C system performance and to protect the A/C system from evaporator freezing. The evaporator temperature sensor will change its internal resistance in response to the temperatures it monitors and is connected to the A/C-heater control through sensor ground circuit and a 5-volt reference signal circuit. As the temperature of the A/C evaporator decreases, the internal resistance of the evaporator temperature sensor decreases. The A/C-heater control uses the monitored voltage reading as an indication of evaporator temperature. The A/C-heater control is programmed to respond to this input by requesting the powertrain control module (PCM) or the engine control module (ECM) (depending on engine application) to adjust the compressor swash plate angle as necessary to optimize A/C system performance and to protect the A/C system from evaporator freezing. The evaporator temperature sensor is diagnosed using a scan tool. The evaporator temperature sensor cannot be adjusted or repaired and it must be replaced if found inoperative or damaged. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Service and Repair > Removal Evaporator Temperature Sensor / Switch: Service and Repair Removal REMOVAL NOTE: Illustration shown with air distribution housing removed for clarity. NOTE: It is not necessary to remove and disassemble the HVAC housing to service the evaporator temperature sensor. The evaporator temperature sensor can be removed for service from underneath the instrument panel. 1. Disconnect and isolate the negative battery cable. 2. Reach up under the driver side of the instrument panel and disconnect the electrical connector for the evaporator temperature sensor (1) from the instrument panel wire harness. 3. Using needle nose pliers, disengage the two retaining tabs (3) that secure the evaporator temperature sensor to the HVAC housing (2) by carefully pulling the sensor straight out of the side of the HVAC housing. 4. Route the electrical connector and wire lead of the evaporator temperature sensor out from under the heater core tubes and remove the sensor from the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Service and Repair > Removal > Page 7594 Evaporator Temperature Sensor / Switch: Service and Repair Installation INSTALLATION NOTE: Illustration shown with air distribution housing removed for clarity. 1. Route the electrical connector and wire lead of the evaporator temperature sensor (1) under the heater core tubes located on the driver side of the HVAC housing (2). 2. Install the evaporator temperature sensor into the driver side of the HVAC housing. Make sure the retaining tabs (3) are fully engaged to the housing. 3. Connect the electrical connector for the evaporator temperature sensor to the instrument panel wire harness. 4. Reconnect the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Refrigerant Pressure Sensor / Switch: Locations Component ID: 360 Component : TRANSDUCER-A/C PRESSURE Connector: Name : TRANSDUCER-A/C PRESSURE Color : GRAY # of pins : 4 Pin Description Circuit 1 A/C PRESSURE SENSOR GROUND C918 20BK/LB 2 A/C PRESSURE SENSOR SUPPLY C818 20LB/TN 3 A/C PRESSURE SENSOR SIGNAL C18 20LB/BR 4-Component Location - 4 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7598 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7599 Refrigerant Pressure Sensor / Switch: Diagrams Component ID: 360 Component : TRANSDUCER-A/C PRESSURE Connector: Name : TRANSDUCER-A/C PRESSURE Color : GRAY # of pins : 4 Pin Description Circuit 1 A/C PRESSURE SENSOR GROUND C918 20BK/LB 2 A/C PRESSURE SENSOR SUPPLY C818 20LB/TN 3 A/C PRESSURE SENSOR SIGNAL C18 20LB/BR 4-Component Location - 4 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7600 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Description Refrigerant Pressure Sensor / Switch: Description and Operation Description DESCRIPTION The A/C pressure transducer (1) is a switch that is installed on a fitting located on the A/C discharge line. An internally threaded fitting on the A/C pressure transducer connects it to the externally threaded Schrader-type fitting on the A/C discharge line. A rubber O-ring seals the connection between the A/C pressure transducer and the discharge line fitting. The A/C pressure transducer is connected to the vehicle electrical system by a molded plastic connector with three terminals. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Description > Page 7603 Refrigerant Pressure Sensor / Switch: Description and Operation Operation OPERATION The A/C pressure transducer monitors the pressures in the high side of the refrigerant system through its connection to a fitting on the A/C discharge line. The internal resistance of the A/C pressure transducer changes in response to the pressures it monitors. The totally integrated power module (TIPM) provides a five volt reference signal and a sensor ground to the A/C pressure transducer. The TIPM then monitors the output voltage of the transducer on a sensor return circuit to determine refrigerant pressure and sends a message to the powertrain control module (PCM) or the engine control module (ECM) (depending on engine application) over the CAN C BUS. The PCM/ECM is programmed to respond to this and other sensor inputs by controlling the operation of the swashplate within the A/C compressor and the radiator cooling fan to help optimize A/C system performance and to protect the system components from damage. The PCM adjusts the swashplate to nearly a zero degree angle (low compressor displacement) when high side pressure rises above 3130 kPa (454 psi) and re-adjusts the swashplate to a greater angle (higher compressor displacement) when high side pressure drops below 1999 kPa (290 psi). The A/C pressure transducer also reduces the swashplate angle if the high side pressure drops below 200 kPa (29 psi) and will increase the swashplate angle when the high side pressure rises above 234 262 kPa (34 - 38 psi). When the refrigerant pressure rises above 1655 kPa (240 psi), the PCM will actuate the cooling fan. A Schrader-type valve in the A/C discharge line fitting permits the A/C pressure transducer to be removed or installed without disturbing the refrigerant in the A/C system. The A/C pressure transducer is diagnosed using a scan tool. The A/C pressure transducer cannot be adjusted or repaired and must be replaced if found inoperative or damaged. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Removal Refrigerant Pressure Sensor / Switch: Service and Repair Removal REMOVAL NOTE: It is not necessary to discharge the refrigerant system to replace the A/C pressure transducer. NOTE: Typical A/C pressure transducer shown. 1. Disconnect and isolate the negative battery cable. 2. Carefully pull the top of the fascia forward to gain access to the A/C pressure transducer (2). 3. Reach down through the opening between the A/C condenser and the front fascia and disconnect the wire harness connector (1) from the A/C pressure transducer located on the A/C discharge line (3). 4. Remove the A/C pressure transducer from the fitting on the A/C discharge line and remove and discard the O-ring seal. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Removal > Page 7606 Refrigerant Pressure Sensor / Switch: Service and Repair Installation INSTALLATION NOTE: Use only the specified O-ring as it is made of special material for R-134a. Use only refrigerant oil of the type required for the A/C compressor. NOTE: Typical A/C pressure transducer shown. 1. Lubricate a new rubber O-ring seal (4) with clean refrigerant oil and install it onto the discharge line fitting (3). 2. Install the A/C pressure transducer (2) onto the A/C discharge line. Tighten the A/C pressure transducer securely. 3. Connect the wire harness connector (1) to the A/C pressure transducer. 4. Reinstall the top of the front fascia. 5. Reconnect the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Description and Operation Service Port HVAC: Description and Operation DESCRIPTION Refrigerant system service ports are used to recover, recycle, evacuate, charge and test the A/C refrigerant system. Unique sizes are used on the two service ports for the R-134a refrigerant system to ensure the system is not accidentally contaminated with R-12 refrigerant or by service equipment used for R-12 refrigerant. The high side service port (1) is located on the A/C discharge line (2) in front of the engine, below the upper radiator hose (3). The low side service port (1) is located on the A/C liquid line (2) near the right front strut tower (3). Both the high side and low side A/C service port valve cores are serviceable. NOTE: The protective cap aids in service port sealing and helps protect the refrigerant system from contamination. Remember to always reinstall the protective cap onto the service port when refrigerant system service is complete. Each of the service ports has a threaded plastic protective cap installed over it from the factory. The service port caps are serviceable items. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Service and Repair > Removal Service Port HVAC: Service and Repair Removal REMOVAL WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions may result in serious or fatal injury. NOTE: Typical A/C service port shown. 1. Remove the protective cap (1) from the service port (2). 2. Recover the refrigerant from the refrigerant system. 3. Using a Schrader-type valve core tool, remove the valve core (3) from the service port. 4. Install a plug in, or tape over the opened service port(s). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Service and Repair > Removal > Page 7612 Service Port HVAC: Service and Repair Installation INSTALLATION NOTE: Typical A/C service port shown. 1. Lubricate the valve core (3) with clean refrigerant oil prior to installation. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 2. Remove the tape or plug from the service port (2). CAUTION: A valve core that is not fully seated in the A/C service port can result in damage to the valve during refrigerant system evacuation and charge. Such damage may result in a loss of system refrigerant while uncoupling the charge adapters. 3. Using a Schrader-type valve core tool, install and tighten the valve core into the service port(s). CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system. Failure to follow this caution will result in serious A/C compressor damage. 4. Evacuate the refrigerant system. 5. Charge the refrigerant system. NOTE: The protective cap helps aid in service port sealing and helps protect the refrigerant system from contamination. Remember to always reinstall the protective cap onto the service port when refrigerant system service is complete. 6. Install the protective cap (1) onto the service port. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair Repairs and Inspections Required After a Collision: Service and Repair SERVICE AFTER AN AIRBAG DEPLOYMENT DRIVER AIRBAG After a Driver Airbag has been deployed due to a collision, the following MUST be replaced: - Driver Airbag - Clockspring Assembly - Steering Wheel - Complete Steering Column Assembly with Lower Steering Column Coupler All other airbag and vehicle components should be closely inspected following any airbag deployment, and should be replaced when visible damage is incurred. WARNING: Do not connect the battery negative cable. Personal injury or death may result if the system test is not performed first. PASSENGER AIRBAG After a Passenger Airbag has been deployed due to a collision. the following MUST be replaced: - Passenger Airbag - Passenger Airbag Cover All other airbag and vehicle components should be closely inspected following any airbag deployment, and should be replaced when visible damage is incurred. WARNING: Do not connect the battery negative cable. Personal injury or death may result if the system test is not performed first. SEAT AIRBAG After a Seat Airbag has been deployed due to a collision, the following MUST be replaced: - Complete Seat Back Assembly All other airbag and vehicle components should be closely inspected following any airbag deployment, and should be replaced when visible damage is incurred. WARNING: Do not connect the battery negative cable. Personal injury or death may result if the system test is not performed first. KNEE BLOCKER AIRBAG After a Knee Blocker Airbag has been deployed due to a collision, the following MUST be replaced: - Knee Blocker Airbag - Knee Blocker Airbag Trim Cover - Instrument Panel and Pad Assembly All other airbag and vehicle components should be closely inspected following any airbag deployment, and should be replaced when visible damage is incurred. WARNING: Do not connect the battery negative cable. Personal injury or death may result if the system test is not performed first. CURTAIN AIRBAG After a Curtain Airbag has been deployed due to a collision. the following MUST be replaced: - Curtain Airbag Assembly - Headliner - A, B, C, and D-pillar trim on deployed side. All other airbag and vehicle components should be closely inspected following any airbag deployment, and should be replaced when visible damage is incurred. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Page 7617 WARNING: Do not connect the battery negative cable. Personal injury or death may result if the system test is not performed first. OCCUPANT CLASSIFICATION SYSTEM (OCS) After an impact event, either front, rear, or side, the OCS system components need to be inspected and replaced if found to be damaged. This includes: - Occupant Classification Module (OCM) - Passenger Airbag Disabled Indicator - Seat Weight Sensors (4) WARNING: Never replace both the Occupant Restraint Controller (ORC) and the Occupant Classification Module (OCM) at the same time. If both require replacement, replace one, then perform the Airbag System test before replacing the other. Both the ORC and the OCM store Occupant Classification System (OCS) calibration data, which they transfer to one another when one of them is replaced. If both are replaced at the same time, an irreversible fault will be set in both modules and the OCS may malfunction and result in personal injury or death. Whether replaced or not, the OCS must be re-zeroed to make sure that the system in within proper parameters to sense the occupants weight correctly. WARNING: Do not connect the battery negative cable. Personal injury or death may result if the system test is not performed first. WARNING: Following successful completion of the Airbag System test procedure, the Occupant Classification System Verification Test must be done using a scan tool and the appropriate diagnostic information. Personal injury or death may result if the system test is not performed. SEAT BELTS AND TENSIONERS After a frontal impact where an airbag has been deployed due to a collision. the following MUST be replaced: - Front Seat Belt Retractors (driver and passenger) with integral Tensioners. All other seat belts should be closely inspected for cuts, tears, fraying, or damage in any way following any frontal impact or airbag deployment. The other seat belts are to be replaced when visible damage is incurred. Inspect the Lower Anchors and Tether for Children (LATCH) child restraint anchors for damage after an impact event and replace as needed. WARNING: Do not connect the battery negative cable. Personal injury or death may result if the system test is not performed first. CLEAN UP PROCEDURE Roll or fold the airbag towards its mounting point (i.e. instrument panel, steering wheel, or seat back). Then tape the ripped cover over the deployed airbag. Use a vacuum cleaner to remove any residual powder from the vehicle interior. Work from the outside in to avoid kneeling or sitting in a contaminated area. Vacuum the heater and A/C outlets as well. If the heater or air conditioner was in RECIRC mode at time of airbag deployment, operate blower motor on low speed and vacuum powder residue expelled from the heater and A/C outlets. Multiple vacuum cleaning may be necessary to decontaminate the interior of the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Knee Blocker-Driver Air Bag: Locations Airbag-Knee Blocker-Driver Component ID: 4 Component : AIRBAG-KNEE BLOCKER-DRIVER Connector: Name : AIRBAG-KNEE BLOCKER-DRIVER Color : YELLOW/BLACK # of pins : 2 Qualifier : (EXCEPT BASE) Pin Description Circuit 1 DRIVER KNEE BLOCKER SQUIB LINE 2 R9 18LB/YL 2 DRIVER KNEE BLOCKER SQUIB LINE 1 R11 18LB/DB Component Location - 23 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Knee Blocker-Driver > Page 7623 Fig. 23 Component Location - 24 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Knee Blocker-Driver > Page 7624 Component Location - 26 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Knee Blocker-Driver > Page 7625 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Knee Blocker-Driver > Page 7626 Air Bag: Locations Airbag-Passenger Squib 1 Component ID: 5 Component : AIRBAG-PASSENGER SQUIB 1 Connector: Name : AIRBAG-PASSENGER SQUIB 1 Color : YELLOW/BLACK # of pins : 2 Qualifier : (EXCEPT BASE) Pin Description Circuit 1 PASSENGER SQUIB 1 LINE 2 R42 18LB/BR 2 PASSENGER SQUIB 1 LINE 1 R44 18LB/OR Component Location - 25 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Knee Blocker-Driver > Page 7627 Component Location - 29 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Knee Blocker-Driver > Page 7628 Fig. 29 Component Location - 31 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Knee Blocker-Driver > Page 7629 Component Location - 33 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Knee Blocker-Driver > Page 7630 Fig. 33 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Knee Blocker-Driver > Page 7631 Air Bag: Locations Airbag-Passenger Squib 2 Component ID: 6 Component : AIRBAG-PASSENGER SQUIB 2 Connector: Name : AIRBAG-PASSENGER SQUIB 2 Color : YELLOW/ORANGE # of pins : 2 Qualifier : (EXCEPT BASE) Pin Description Circuit 1 PASSENGER SQUIB 2 LINE 2 R62 18LB/VT 2 PASSENGER SQUIB 2 LINE 1 R64 18LB/WT Component Location - 25 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Knee Blocker-Driver > Page 7632 Component Location - 29 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Knee Blocker-Driver > Page 7633 Fig. 29 Component Location - 31 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Knee Blocker-Driver > Page 7634 Component Location - 33 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Knee Blocker-Driver > Page 7635 Fig. 33 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Knee Blocker-Driver > Page 7636 Air Bag: Locations Airbag-Side Curtain-Right Component ID: 8 Component : AIRBAG-SIDE CURTAIN-RIGHT Connector: Name : AIRBAG-SIDE CURTAIN-RIGHT Color : YELLOW/BLACK # of pins : 2 Pin Description Circuit 1 RIGHT CURTAIN SQUIB 1 LINE 1 R4 18OR/LB 2 RIGHT CURTAIN SQUIB 1 LINE 2 R2 18WT/LB Component Location - 63 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Knee Blocker-Driver > Page 7637 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Knee Blocker-Driver > Page 7638 Air Bag: Locations Airbag-Knee Blocker-Driver Component ID: 4 Component : AIRBAG-KNEE BLOCKER-DRIVER Connector: Name : AIRBAG-KNEE BLOCKER-DRIVER Color : YELLOW/BLACK # of pins : 2 Qualifier : (EXCEPT BASE) Pin Description Circuit 1 DRIVER KNEE BLOCKER SQUIB LINE 2 R9 18LB/YL 2 DRIVER KNEE BLOCKER SQUIB LINE 1 R11 18LB/DB Component Location - 23 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Knee Blocker-Driver > Page 7639 Fig. 23 Component Location - 24 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Knee Blocker-Driver > Page 7640 Component Location - 26 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Knee Blocker-Driver > Page 7641 Airbag-Passenger Squib 1 Component ID: 5 Component : AIRBAG-PASSENGER SQUIB 1 Connector: Name : AIRBAG-PASSENGER SQUIB 1 Color : YELLOW/BLACK # of pins : 2 Qualifier : (EXCEPT BASE) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Knee Blocker-Driver > Page 7642 Pin Description Circuit 1 PASSENGER SQUIB 1 LINE 2 R42 18LB/BR 2 PASSENGER SQUIB 1 LINE 1 R44 18LB/OR Component Location - 25 Component Location - 29 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Knee Blocker-Driver > Page 7643 Fig. 29 Component Location - 31 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Knee Blocker-Driver > Page 7644 Component Location - 33 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Knee Blocker-Driver > Page 7645 Fig. 33 Airbag-Passenger Squib 2 Component ID: 6 Component : AIRBAG-PASSENGER SQUIB 2 Connector: Name : AIRBAG-PASSENGER SQUIB 2 Color : YELLOW/ORANGE # of pins : 2 Qualifier : (EXCEPT BASE) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Knee Blocker-Driver > Page 7646 Pin Description Circuit 1 PASSENGER SQUIB 2 LINE 2 R62 18LB/VT 2 PASSENGER SQUIB 2 LINE 1 R64 18LB/WT Component Location - 25 Component Location - 29 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Knee Blocker-Driver > Page 7647 Fig. 29 Component Location - 31 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Knee Blocker-Driver > Page 7648 Component Location - 33 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Knee Blocker-Driver > Page 7649 Fig. 33 Airbag-Side Curtain-Right Component ID: 8 Component : AIRBAG-SIDE CURTAIN-RIGHT Connector: Name : AIRBAG-SIDE CURTAIN-RIGHT Color : YELLOW/BLACK # of pins : 2 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Knee Blocker-Driver > Page 7650 Pin Description Circuit 1 RIGHT CURTAIN SQUIB 1 LINE 1 R4 18OR/LB 2 RIGHT CURTAIN SQUIB 1 LINE 2 R2 18WT/LB Component Location - 63 Sensor-Front Impact-Right Component ID: 294 Component : SENSOR-FRONT IMPACT-RIGHT Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Knee Blocker-Driver > Page 7651 Connector: Name : SENSOR-FRONT IMPACT-RIGHT Color : YELLOW # of pins : 2 Pin Description Circuit 1 RIGHT FRONT IMPACT SENSOR GROUND R82 20WT/OR 2 RIGHT FRONT IMPACT SENSOR SIGNAL R80 20VT/LB Component Location - 4 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Knee Blocker-Driver > Page 7652 Airbag-Driver Squib 1 Component ID: 2 Component : AIRBAG-DRIVER SQUIB 1 Connector: Name : AIRBAG-DRIVER SQUIB 1 Color : BLACK/YELLOW # of pins : 2 Pin Description Circuit Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Knee Blocker-Driver > Page 7653 1 DRIVER SQUIB 1 LINE 1 R45 20LB 2 DRIVER SQUIB 1 LINE 2 R43 20BR Component Location - 26 Component Location - 32 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Knee Blocker-Driver > Page 7654 Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Knee Blocker-Driver > Page 7655 Airbag-Driver Squib 2 Component ID: 3 Component : AIRBAG-DRIVER SQUIB 2 Connector: Name : AIRBAG-DRIVER SQUIB 2 Color : NATURAL/YELLOW # of pins : 2 Pin Description Circuit Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Knee Blocker-Driver > Page 7656 1 DRIVER SQUIB 2 LINE 1 R63 20RD 2 DRIVER SQUIB 2 LINE 2 R61 20YL Component Location - 26 Component Location - 32 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Knee Blocker-Driver > Page 7657 Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Knee Blocker-Driver > Page 7658 Airbag-Side Curtain-Left Component ID: 7 Component : AIRBAG-SIDE CURTAIN-LEFT Connector: Name : AIRBAG-SIDE CURTAIN-LEFT Color : YELLOW/BLACK # of pins : 2 Pin Description Circuit Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Knee Blocker-Driver > Page 7659 1 LEFT CURTAIN SQUIB 1 LINE 2 R1 18LB/WT 2 LEFT CURTAIN SQUIB 1 LINE 1 R3 18LB/OR Component Location - 65 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Knee Blocker-Driver Air Bag: Diagrams Airbag-Knee Blocker-Driver Component ID: 4 Component : AIRBAG-KNEE BLOCKER-DRIVER Connector: Name : AIRBAG-KNEE BLOCKER-DRIVER Color : YELLOW/BLACK # of pins : 2 Qualifier : (EXCEPT BASE) Pin Description Circuit 1 DRIVER KNEE BLOCKER SQUIB LINE 2 R9 18LB/YL 2 DRIVER KNEE BLOCKER SQUIB LINE 1 R11 18LB/DB Component Location - 23 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Knee Blocker-Driver > Page 7662 Fig. 23 Component Location - 24 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Knee Blocker-Driver > Page 7663 Component Location - 26 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Knee Blocker-Driver > Page 7664 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Knee Blocker-Driver > Page 7665 Air Bag: Diagrams Airbag-Passenger Squib 1 Component ID: 5 Component : AIRBAG-PASSENGER SQUIB 1 Connector: Name : AIRBAG-PASSENGER SQUIB 1 Color : YELLOW/BLACK # of pins : 2 Qualifier : (EXCEPT BASE) Pin Description Circuit 1 PASSENGER SQUIB 1 LINE 2 R42 18LB/BR 2 PASSENGER SQUIB 1 LINE 1 R44 18LB/OR Component Location - 25 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Knee Blocker-Driver > Page 7666 Component Location - 29 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Knee Blocker-Driver > Page 7667 Fig. 29 Component Location - 31 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Knee Blocker-Driver > Page 7668 Component Location - 33 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Knee Blocker-Driver > Page 7669 Fig. 33 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Knee Blocker-Driver > Page 7670 Air Bag: Diagrams Airbag-Passenger Squib 2 Component ID: 6 Component : AIRBAG-PASSENGER SQUIB 2 Connector: Name : AIRBAG-PASSENGER SQUIB 2 Color : YELLOW/ORANGE # of pins : 2 Qualifier : (EXCEPT BASE) Pin Description Circuit 1 PASSENGER SQUIB 2 LINE 2 R62 18LB/VT 2 PASSENGER SQUIB 2 LINE 1 R64 18LB/WT Component Location - 25 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Knee Blocker-Driver > Page 7671 Component Location - 29 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Knee Blocker-Driver > Page 7672 Fig. 29 Component Location - 31 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Knee Blocker-Driver > Page 7673 Component Location - 33 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Knee Blocker-Driver > Page 7674 Fig. 33 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Knee Blocker-Driver > Page 7675 Air Bag: Diagrams Airbag-Side Curtain-Right Component ID: 8 Component : AIRBAG-SIDE CURTAIN-RIGHT Connector: Name : AIRBAG-SIDE CURTAIN-RIGHT Color : YELLOW/BLACK # of pins : 2 Pin Description Circuit 1 RIGHT CURTAIN SQUIB 1 LINE 1 R4 18OR/LB 2 RIGHT CURTAIN SQUIB 1 LINE 2 R2 18WT/LB Component Location - 63 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Knee Blocker-Driver > Page 7676 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Knee Blocker-Driver > Page 7677 Air Bag: Diagrams Airbag-Knee Blocker-Driver Component ID: 4 Component : AIRBAG-KNEE BLOCKER-DRIVER Connector: Name : AIRBAG-KNEE BLOCKER-DRIVER Color : YELLOW/BLACK # of pins : 2 Qualifier : (EXCEPT BASE) Pin Description Circuit 1 DRIVER KNEE BLOCKER SQUIB LINE 2 R9 18LB/YL 2 DRIVER KNEE BLOCKER SQUIB LINE 1 R11 18LB/DB Component Location - 23 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Knee Blocker-Driver > Page 7678 Fig. 23 Component Location - 24 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Knee Blocker-Driver > Page 7679 Component Location - 26 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Knee Blocker-Driver > Page 7680 Airbag-Passenger Squib 1 Component ID: 5 Component : AIRBAG-PASSENGER SQUIB 1 Connector: Name : AIRBAG-PASSENGER SQUIB 1 Color : YELLOW/BLACK # of pins : 2 Qualifier : (EXCEPT BASE) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Knee Blocker-Driver > Page 7681 Pin Description Circuit 1 PASSENGER SQUIB 1 LINE 2 R42 18LB/BR 2 PASSENGER SQUIB 1 LINE 1 R44 18LB/OR Component Location - 25 Component Location - 29 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Knee Blocker-Driver > Page 7682 Fig. 29 Component Location - 31 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Knee Blocker-Driver > Page 7683 Component Location - 33 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Knee Blocker-Driver > Page 7684 Fig. 33 Airbag-Passenger Squib 2 Component ID: 6 Component : AIRBAG-PASSENGER SQUIB 2 Connector: Name : AIRBAG-PASSENGER SQUIB 2 Color : YELLOW/ORANGE # of pins : 2 Qualifier : (EXCEPT BASE) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Knee Blocker-Driver > Page 7685 Pin Description Circuit 1 PASSENGER SQUIB 2 LINE 2 R62 18LB/VT 2 PASSENGER SQUIB 2 LINE 1 R64 18LB/WT Component Location - 25 Component Location - 29 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Knee Blocker-Driver > Page 7686 Fig. 29 Component Location - 31 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Knee Blocker-Driver > Page 7687 Component Location - 33 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Knee Blocker-Driver > Page 7688 Fig. 33 Airbag-Side Curtain-Right Component ID: 8 Component : AIRBAG-SIDE CURTAIN-RIGHT Connector: Name : AIRBAG-SIDE CURTAIN-RIGHT Color : YELLOW/BLACK # of pins : 2 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Knee Blocker-Driver > Page 7689 Pin Description Circuit 1 RIGHT CURTAIN SQUIB 1 LINE 1 R4 18OR/LB 2 RIGHT CURTAIN SQUIB 1 LINE 2 R2 18WT/LB Component Location - 63 Sensor-Front Impact-Right Component ID: 294 Component : SENSOR-FRONT IMPACT-RIGHT Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Knee Blocker-Driver > Page 7690 Connector: Name : SENSOR-FRONT IMPACT-RIGHT Color : YELLOW # of pins : 2 Pin Description Circuit 1 RIGHT FRONT IMPACT SENSOR GROUND R82 20WT/OR 2 RIGHT FRONT IMPACT SENSOR SIGNAL R80 20VT/LB Component Location - 4 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Knee Blocker-Driver > Page 7691 Airbag-Driver Squib 1 Component ID: 2 Component : AIRBAG-DRIVER SQUIB 1 Connector: Name : AIRBAG-DRIVER SQUIB 1 Color : BLACK/YELLOW # of pins : 2 Pin Description Circuit Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Knee Blocker-Driver > Page 7692 1 DRIVER SQUIB 1 LINE 1 R45 20LB 2 DRIVER SQUIB 1 LINE 2 R43 20BR Component Location - 26 Component Location - 32 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Knee Blocker-Driver > Page 7693 Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Knee Blocker-Driver > Page 7694 Airbag-Driver Squib 2 Component ID: 3 Component : AIRBAG-DRIVER SQUIB 2 Connector: Name : AIRBAG-DRIVER SQUIB 2 Color : NATURAL/YELLOW # of pins : 2 Pin Description Circuit Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Knee Blocker-Driver > Page 7695 1 DRIVER SQUIB 2 LINE 1 R63 20RD 2 DRIVER SQUIB 2 LINE 2 R61 20YL Component Location - 26 Component Location - 32 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Knee Blocker-Driver > Page 7696 Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Knee Blocker-Driver > Page 7697 Airbag-Side Curtain-Left Component ID: 7 Component : AIRBAG-SIDE CURTAIN-LEFT Connector: Name : AIRBAG-SIDE CURTAIN-LEFT Color : YELLOW/BLACK # of pins : 2 Pin Description Circuit Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Knee Blocker-Driver > Page 7698 1 LEFT CURTAIN SQUIB 1 LINE 2 R1 18LB/WT 2 LEFT CURTAIN SQUIB 1 LINE 1 R3 18LB/OR Component Location - 65 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Curtain Airbag Air Bag: Description and Operation Curtain Airbag Description DESCRIPTION Curtain airbags are available when also equipped with dual front airbags. These airbags are passive, inflatable, Supplemental Restraint System (SRS) components, and can be readily identified by a molded identification trim button with the "SRS - AIRBAG" logo located near the top of each upper B-pillar trim panel. This system is designed to reduce injuries to the vehicle occupants in the event of a side impact collision. Curtain airbags have two individually controlled curtain airbags. These airbags are concealed and mounted above the headliner where they are each secured to one of the roof side rails. Each folded airbag cushion extends along the roof rail from the A-pillar at the front of the vehicle to the D-pillar at the rear of the vehicle. The airbag cushion is initially secured during installation with plastic push-in fasteners to the roof rail, and then with bolts to securely fasten it to the roof side rail. A long tether (2) extends down the A-pillar from the front of the airbag cushion. A short tether (4) is secured near the top of the D-pillar. The hybrid-type inflator (1) for each airbag is secured to the roof rail at the rear of airbag, back by the C and D-pillars. The entire assembly is secured to the inside of the roof rail with screws. An airbag squib harness connector is routed up to the rear of the airbag inflator (1). The body harness then connects the curtain airbag to the Occupant Restraint Controller (ORC). The curtain airbag cannot be adjusted or repaired and must be replaced if deployed, faulty, or in any way damaged. Once a curtain airbag has been deployed, the complete airbag, the headliner, the upper A, B, C and D-pillar trim, and all other visibly damaged components must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Curtain Airbag > Page 7701 Operation OPERATION Each curtain airbag is deployed individually by an electrical signal generated by the Occupant Restraint Controller (ORC) to which it is connected through squib circuits. The hybrid-type inflator assembly for each airbag contains a small canister of highly compressed inert gas. When the ORC sends the proper electrical signal to the airbag inflator, the electrical energy creates enough heat to ignite chemical pellets within the inflator. Once ignited, these chemicals burn rapidly and produce the pressure necessary to rupture a containment disk in the inert gas canister. The inflator and inert gas canister are sealed and connected to a tubular manifold so that all of the released gas is directed into the folded curtain airbag cushion, causing the cushion to inflate. As the airbag cushion inflates it will drop down from the roof rail between the edge of the headliner and the side glass/body pillars to form a curtain-like cushion to protect the vehicle occupants during a side impact collision. The front and rear tethers keep the airbag cushion taut to the side of the vehicle, thus ensuring that the bag will deploy in the proper position. Following the airbag deployment, the airbag cushion quickly deflates by venting the inert gas through the loose weave of the cushion fabric, and the deflated cushion hangs down loosely from the roof rail. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Curtain Airbag > Page 7702 Air Bag: Description and Operation Driver Airbag Description DESCRIPTION The driver airbag protective trim cover (1) is the most visible part of the driver airbag system. The driver airbag trim cover is held in place by a latch and hook system (1). The driver airbag is mounted directly to the steering wheel by two bolts on either side of the airbag (3). Located under the airbag cover are the folded airbag cushion, the igniter and two squib connectors (2), the inflator, and the airbag cushion supporting components. The driver airbag is a multistage-type that is designed to deploy with less force than those used in some prior models. A radial deploying fabric airbag cushion with internal tethers is used. The airbag inflator is a dual-initiator, non-azide, pyrotechnic-type unit. Two keyed and color-coded connector receptacles on the driver airbag inflator connect the two inflator initiators to the vehicle electrical system through two yellow-jacketed, two-wire pigtail harnesses of the clockspring. The driver airbag cannot be repaired, and must be replaced if deployed or in any way damaged. The driver airbag trim cover may be disassembled from the driver airbag unit, and is available for individual service replacement. Operation OPERATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Curtain Airbag > Page 7703 The multistage driver airbag is deployed by electrical signals generated by the Occupant Restraint Controller (ORC) through the driver airbag squib 1 and squib 2 circuits to the two initiators in the airbag inflator. By using two initiators, the airbag can be deployed at multiple levels of force. The force level is controlled by the ORC to suit the monitored impact conditions by providing one of four delay intervals between the electrical signals provided to the two initiators. The longer the delay between these signals, the less forcefully the airbag will deploy. When the ORC sends the proper electrical signals to each initiator, the electrical energy generates enough heat to initiate a small pyrotechnic charge which, in turn ignites chemical pellets within the inflator. Once ignited, these chemical pellets burn rapidly and produce a large quantity of inert gas. The inflator is sealed to the back of the airbag housing and a diffuser in the inflator directs all of the inert gas into the airbag cushion, causing the cushion to inflate. As the cushion inflates, the driver airbag trim cover will split at predetermined breakout lines, then fold back out of the way along with the horn switch and tray unit. Following an airbag deployment, the airbag cushion quickly deflates by venting the inert gas towards the instrument panel through vent holes within the fabric used to construct the back (steering wheel side) panel of the airbag cushion. Some of the chemicals used to create the inert gas may be considered hazardous while in their solid state before they are burned, but they are securely sealed within the airbag inflator. Typically, both initiators are used and all potentially hazardous chemicals are burned during an airbag deployment event. The inert gas that is produced when the chemicals are burned is harmless. However, a small amount of residue from the burned chemicals may cause some temporary discomfort if it contacts the skin, eyes, or breathing passages. If skin or eye irritation is noted, rinse the affected area with plenty of cool, clean water. If breathing passages are irritated, move to another area where there is plenty of clean, fresh air to breath. If the irritation is not alleviated by these actions, contact a physician. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Curtain Airbag > Page 7704 Air Bag: Description and Operation Airbag-Knee Blocker Description DESCRIPTION The Knee Blocker Airbag is located on the driver side of the vehicle below the steering column, at the bottom edge of the instrument panel. The knee blocker airbag contains: - A stamped steel housing (4) with retaining hooks (1) for the knee blocker airbag trim cover to attach to. - An airbag cushion (2) - An igniter (3) WARNING: Following a knee blocker airbag deployment, the knee blocker airbag and instrument panel assembly must be replaced. Refer to the proper diagnostic information for diagnosis and testing. Operation OPERATION The knee blocker airbag is equipped with a single inflator. When the Occupant Restraint Controller (ORC) sends the proper electrical signals to the initiator, the electrical energy generates enough heat to initiate a small pyrotechnic charge which, in turn ignites chemical pellets within the inflator. Once ignited, these chemical pellets burn rapidly and produce a large quantity of inert gas. The inflator is sealed to the back of the airbag housing and a diffuser in the inflator directs all of the inert gas into the airbag cushion, causing the cushion to inflate. As the cushion inflates, the knee blocker airbag trim deploy. Following an airbag deployment, the airbag cushion quickly deflates by venting the inert gas towards the instrument panel through vent holes within the fabric used to construct the back panel of the airbag cushion. Some of the chemicals used to create the inert gas may be considered hazardous while in their solid state before they are burned, but they are securely sealed within the airbag inflator. Typically, the potentially hazardous chemicals are burned during an airbag deployment event. WARNING: The inert gas that is produced when the chemicals are burned is harmless. However, a small amount of residue from the burned chemicals may cause some temporary discomfort if it contacts the skin, eyes, or breathing passages. If skin or eye irritation is noted, rinse the affected area with plenty of cool, clean water. If breathing passages are irritated, move to another area where there is plenty of clean, fresh air to breath. If the irritation is not alleviated by these actions, contact a physician. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Curtain Airbag > Page 7705 Air Bag: Description and Operation Passenger Airbag Description DESCRIPTION The horizontal surface of the instrument panel top panel (2) above the glove box (3) is the most visible part of the Passenger Airbag (PAB). The PAB door/cover is available for separate service replacement. The PAB includes an aluminum housing (2) within which the cushion (1) and inflator (3) are mounted and sealed. A stamped metal bracket mounts the PAB to the instrument panel. It is mounted directly to the instrument panel reinforcement. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Curtain Airbag > Page 7706 The bottom of the PAB houses the inflater (2). It is attached to the PAB by four nuts (1) and contains the two squib connectors (3) which connect the PAB to the vehicle electrical system through the instrument panel wire harness. Following a PAB deployment, the PAB and the PAB cover must be replaced. The PAB cannot be repaired, and must be replaced if deployed or in any way damaged. Operation OPERATION The multistage Passenger Airbag (PAB) is deployed by electrical signals generated by the Occupant Restraint Controller (ORC) through the PAB squib 1 and squib 2 circuits to the two initiators in the airbag inflator. By using two initiators, the airbag can be deployed at multiple levels of force. The force level is controlled by the ORC to suit the monitored impact conditions by providing one of four delay intervals between the electrical signals provided to the two initiators. The longer the delay between these signals, the less forcefully the airbag will deploy. When the ORC sends the proper electrical signals to each initiator, the electrical energy generates enough heat to initiate a small pyrotechnic charge which, in turn ignites chemical pellets within the inflator. Once ignited, these chemical pellets burn rapidly and produce a large quantity of inert gas. The inflator is sealed to the airbag cushion and a diffuser in the inflator directs all of the inert gas into the airbag cushion, causing the cushion to inflate. As the cushion inflates, the PAB cover will split at predetermined tear seam lines concealed on the underside of the PAB cover, then the door will pivot up over the top of the instrument panel and out of the way. Following an airbag deployment, the airbag cushion quickly deflates by venting the inert gas through vent holes within the fabric used to construct the back (windshield side) of the airbag cushion. Proper diagnosis of the PAB inflator and squib circuits requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Curtain Airbag > Page 7707 Air Bag: Description and Operation Seat Airbag Description DESCRIPTION The seat airbags are completely concealed beneath the seat back trim cover on the upper outboard sides of both front seat backs. These airbags are inserted into a sewn pouch on the inside of the trim cover, then secured to the seat back frame by nuts on two studs (3). One stud is located on the stamped metal airbag housing (2), while the second stud is located on the stamped metal airbag lower bracket (4). The folded seat airbag cushions are contained within a molded plastic inner airbag cushion cover (1). The airbag housing contains the airbag inflator and a heat shield. The inner cover completely encloses the airbag cushion and is permanently retained to the housing. The airbag cushion is constructed of a coated nylon fabric. The airbag inflator is a single-initiator, pyrotechnic-type unit that is secured to and sealed within the airbag housing. The seat airbag is connected to the vehicle electrical system through a dedicated take out of the seat wire harness with a connector insulator that connects directly to the inflator initiator. The connector insulators are uniquely keyed and color-coded to ensure they can only be connected to the initiator. The seat airbag cannot be repaired, and must be replaced if deployed, ineffective, or in any way damaged. If the seat airbag is deployed, the seat back frame, the seat back foam, the seat back trim cover and the seat wire harness must also be replaced. Operation OPERATION Each seat airbag is deployed individually by an electrical signal generated by the Occupant Restraint Controller (ORC) to which it is connected through left or right seat airbag line 1 and line 2 (or squib) circuits. The hybrid-type inflator assembly for each airbag contains a small canister of highly compressed inert gas. When the ORC sends the proper electrical signal to the airbag inflator, the electrical energy creates enough heat to ignite chemical pellets within the inflator. Once ignited, these chemicals burn rapidly and produce the pressure necessary to rupture a containment disk in the inert gas canister. The inflator and inert gas canister are sealed and connected so that all of the released gas is directed into the folded seat airbag cushion, causing the cushion to inflate. As the airbag cushion inflates it will split the inner cover and the outboard side of the seat back trim cover and expand into the area between the outboard side of the front seat and the front door to form a cushion to protect the front seat occupant during a side impact collision or a vehicle rollover incident. Following the airbag deployment, the airbag cushion slowly deflates by venting the inert gas through the loose weave of the cushion fabric, and the deflated cushion hangs down loosely from the outboard side of the front seat back. Proper diagnosis of the seat airbag inflator and squib circuits requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag-Driver Air Bag: Service and Repair Airbag-Driver Removal REMOVAL 1. Open hood. 2. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the system reserve capacitor to discharge before servicing any airbag components. 3. From behind the steering wheel (2), gently pry off the driver airbag bolt covers. 4. Remove the two driver airbag attaching bolts (1). 5. Pull airbag rearward and disconnect the two airbag squib connectors (3). 6. Remove airbag (4) from vehicle. WARNING: When replacing a deployed driver airbag, the clockspring MUST also be replaced. Installation INSTALLATION 1. Connect the squib wires (3) to the driver airbag (4). Make airbag connection by pressing straight in on the connector. The connector should be fully seated. Feel for positive snap to assure positive connection. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag-Driver > Page 7710 2. Position the driver airbag (4) in the steering wheel (2) and push forward. NOTE: Make sure not to pinch any wires underneath the driver airbag. 3. Install the two airbag retaining bolts (1). Tighten bolts to 10 Nm (89 in. lbs.). 4. Install the airbag bolt access covers. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. FOR THE SYSTEM TEST, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Supplemental Restraints Verification Test Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag-Driver > Page 7711 Air Bag: Service and Repair Curtain Airbag Removal REMOVAL 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. 2. Lower the headliner from the roof panel. 3. Disconnect the curtain airbag squib connector (2) from the inflator (1). 4. Remove the push pin and unhook the front tether (2) from the A-pillar (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag-Driver > Page 7712 5. Remove the push pin (2) and unhook (1) the rear tether (3) from the D-pillar. 6. Remove the bolts (2) that secure the curtain airbag (3) to the spring nuts in the roof side rail (4). 7. The curtain airbag will be held in place with push pins (1). Release the push pins and remove bag (3) from vehicle. Installation INSTALLATION NOTE: When replacing a curtain airbag because of deployment, the headliner must be replaced as well, including any damaged interior components. 1. Position the curtain airbag in vehicle along roof side rail (4) and install by fastening to roof side rail with integral push fasteners (1). 2. Install the bolts (2) holding the curtain to the roof side rail. Tighten bolts to 8 Nm (71 in. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag-Driver > Page 7713 3. Clip the front tether (2) to the A-pillar (1) and secure push fastener. 4. Clip the rear tether (3) hook (1) to the D-pillar and secure push fastener (2). 5. Connect the curtain airbag squib connector (2) to the inflator (1). 6. Install the headliner back up in place on the roof panel. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. FOR THE SYSTEM TEST, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Supplemental Restraints Verification Test Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag-Driver > Page 7714 Air Bag: Service and Repair Airbag-Knee Blocker Removal REMOVAL 1. Open hood, disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. 2. Remove the two lower knee blocker airbag trim cover (5) screws (4). 3. Reach up behind the knee blocker airbag (1) and remove the two outside nuts (3) holding the airbag to the instrument panel (2). Do not remove the middle nut, it holds the airbag cushion to the back panel. If it is removed by accident, this is a smaller flanged nut than the outside nuts to allow it to pass through the larger middle hole. 4. Pull the knee blocker airbag rearward. 5. Disconnect the knee blocker airbag electrical connector and remove airbag from vehicle. Installation INSTALLATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag-Driver > Page 7715 1. Connect the knee blocker airbag electrical connector by pushing firmly until it snaps into place. 2. Position the knee blocker airbag with trim cover (5) in the instrument panel cavity. 3. Reach up behind the instrument panel and install the two outer knee blocker airbag retaining nuts (3). Tighten nuts to 10.5 Nm (93 in. lbs.). If the middle nut was removed by accident, this is the smaller flanged nut than the outside nuts to allow it to pass through the larger middle hole. 4. Install the two knee blocker airbag cover (5) screws (4). WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. FOR THE SYSTEM TEST, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Supplemental Restraints Verification Test Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag-Driver > Page 7716 Air Bag: Service and Repair Passenger Airbag Removal REMOVAL NON-DEPLOYED AIRBAG 1. Open hood. 2. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. 3. Remove both left and right A-pillar trim panels. 4. Remove instrument panel top cover. 5. Remove the glove box. 6. Remove two fasteners (2) retaining PAB to instrument panel assembly inside glove box opening. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag-Driver > Page 7717 7. Partially raise airbag cover and airbag unit to gain access to the squib connectors. 8. Disconnect the instrument panel wiring routing clip (1). 9. Disconnect the two PAB squib connectors (1). 10. Remove PAB from vehicle. DEPLOYED AIRBAG 1. Open hood. 2. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. 3. Roll/fold PAB towards instrument panel. 4. Close door over folded airbag and tape door closed. 5. Remove both left and right A-pillar trim panels. 6. Remove instrument panel top cover. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag-Driver > Page 7718 7. Remove the glove box. 8. Partially raise airbag cover and airbag unit to gain access to the squib connectors. 9. Disconnect the instrument panel wiring routing clip (1). 10. Disconnect the two PAB squib connectors (1). 11. Remove PAB from vehicle. Installation INSTALLATION 1. 1.Position PAB into instrument panel opening. 2. Connect the two PAB squib connectors (1). 3. Install air bag unit into the instrument panel opening. 4. Install the two retaining nuts (2) retaining PAB to instrument panel assembly inside glove box opening. Tighten to 9.5 Nm (84 in. lbs.). 5. Install instrument panel top cover. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag-Driver > Page 7719 6. Connect wiring harness routing clip to the lower pillar. 7. Install the right and left A-pillar trim panels. 8. Install the glove box. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. FOR THE SYSTEM TEST, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Supplemental Restraints Verification Test Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag-Driver > Page 7720 Air Bag: Service and Repair Removal REMOVAL 1. Open hood. 2. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the system reserve capacitor to discharge before servicing any airbag components. 3. From behind the steering wheel (2), gently pry off the driver airbag bolt covers. 4. Remove the two driver airbag attaching bolts (1). 5. Pull airbag rearward and disconnect the two airbag squib connectors (3). 6. Remove airbag (4) from vehicle. WARNING: When replacing a deployed driver airbag, the clockspring MUST also be replaced. Installation INSTALLATION 1. Connect the squib wires (3) to the driver airbag (4). Make airbag connection by pressing straight in on the connector. The connector should be fully seated. Feel for positive snap to assure positive connection. 2. Position the driver airbag (4) in the steering wheel (2) and push forward. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag-Driver > Page 7721 NOTE: Make sure not to pinch any wires underneath the driver airbag. 3. Install the two airbag retaining bolts (1). Tighten bolts to 10 Nm (89 in. lbs.). 4. Install the airbag bolt access covers. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. FOR THE SYSTEM TEST, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Supplemental Restraints Verification Test Removal REMOVAL 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. 2. Lower the headliner from the roof panel. 3. Disconnect the curtain airbag squib connector (2) from the inflator (1). 4. Remove the push pin and unhook the front tether (2) from the A-pillar (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag-Driver > Page 7722 5. Remove the push pin (2) and unhook (1) the rear tether (3) from the D-pillar. 6. Remove the bolts (2) that secure the curtain airbag (3) to the spring nuts in the roof side rail (4). 7. The curtain airbag will be held in place with push pins (1). Release the push pins and remove bag (3) from vehicle. Installation INSTALLATION NOTE: When replacing a curtain airbag because of deployment, the headliner must be replaced as well, including any damaged interior components. 1. Position the curtain airbag in vehicle along roof side rail (4) and install by fastening to roof side rail with integral push fasteners (1). 2. Install the bolts (2) holding the curtain to the roof side rail. Tighten bolts to 8 Nm (71 in. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag-Driver > Page 7723 3. Clip the front tether (2) to the A-pillar (1) and secure push fastener. 4. Clip the rear tether (3) hook (1) to the D-pillar and secure push fastener (2). 5. Connect the curtain airbag squib connector (2) to the inflator (1). 6. Install the headliner back up in place on the roof panel. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. FOR THE SYSTEM TEST, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Supplemental Restraints Verification Test Removal Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag-Driver > Page 7724 REMOVAL 1. Open hood, disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. 2. Remove the two lower knee blocker airbag trim cover (5) screws (4). 3. Reach up behind the knee blocker airbag (1) and remove the two outside nuts (3) holding the airbag to the instrument panel (2). Do not remove the middle nut, it holds the airbag cushion to the back panel. If it is removed by accident, this is a smaller flanged nut than the outside nuts to allow it to pass through the larger middle hole. 4. Pull the knee blocker airbag rearward. 5. Disconnect the knee blocker airbag electrical connector and remove airbag from vehicle. Installation INSTALLATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag-Driver > Page 7725 1. Connect the knee blocker airbag electrical connector by pushing firmly until it snaps into place. 2. Position the knee blocker airbag with trim cover (5) in the instrument panel cavity. 3. Reach up behind the instrument panel and install the two outer knee blocker airbag retaining nuts (3). Tighten nuts to 10.5 Nm (93 in. lbs.). If the middle nut was removed by accident, this is the smaller flanged nut than the outside nuts to allow it to pass through the larger middle hole. 4. Install the two knee blocker airbag cover (5) screws (4). WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. FOR THE SYSTEM TEST, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Supplemental Restraints Verification Test Removal REMOVAL NON-DEPLOYED AIRBAG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag-Driver > Page 7726 1. Open hood. 2. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. 3. Remove both left and right A-pillar trim panels. 4. Remove instrument panel top cover. 5. Remove the glove box. 6. Remove two fasteners (2) retaining PAB to instrument panel assembly inside glove box opening. 7. Partially raise airbag cover and airbag unit to gain access to the squib connectors. 8. Disconnect the instrument panel wiring routing clip (1). 9. Disconnect the two PAB squib connectors (1). 10. Remove PAB from vehicle. DEPLOYED AIRBAG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag-Driver > Page 7727 1. Open hood. 2. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. 3. Roll/fold PAB towards instrument panel. 4. Close door over folded airbag and tape door closed. 5. Remove both left and right A-pillar trim panels. 6. Remove instrument panel top cover. 7. Remove the glove box. 8. Partially raise airbag cover and airbag unit to gain access to the squib connectors. 9. Disconnect the instrument panel wiring routing clip (1). 10. Disconnect the two PAB squib connectors (1). 11. Remove PAB from vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag-Driver > Page 7728 Installation INSTALLATION 1. 1.Position PAB into instrument panel opening. 2. Connect the two PAB squib connectors (1). 3. Install air bag unit into the instrument panel opening. 4. Install the two retaining nuts (2) retaining PAB to instrument panel assembly inside glove box opening. Tighten to 9.5 Nm (84 in. lbs.). 5. Install instrument panel top cover. 6. Connect wiring harness routing clip to the lower pillar. 7. Install the right and left A-pillar trim panels. 8. Install the glove box. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. FOR THE SYSTEM TEST, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Supplemental Restraints Verification Test Removal REMOVAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag-Driver > Page 7729 1. Position the front seat to its most forward position for easiest access to the front seat mounting hardware. 2. Disconnect and isolate the battery negative cable. wait two minutes for the system capacitor to discharge before further service. 3. Remove the front seat from the vehicle. CAUTION: During removal of the seat back trim cover, be certain not to tear or damage the integral nylon pouch that contains the seat airbag. If the nylon pouch or the trim cover are torn or damaged, the entire front seat back trim cover must be replaced with a new unit. 4. Remove the trim from the front and back of the front seat back (2), but do not remove from the outboard side of the seat back until after the seat airbag has been detached from the seat. CAUTION: Do not pull on the seat wire harness (4) take out or pry on the connector insulator to disengage the connector from the seat airbag (1) inflator connector receptacle. Improper removal of this take out and its connector insulator can result in damage to the airbag circuits or the connector insulator. 5. Disconnect the seat wire harness connector from the seat airbag inflator. Slide the yellow locking tab down then squeeze the two latch tabs on the connector insulator, then pull the insulator straight out from the airbag inflator to disconnect it from the connector receptacle. 6. Remove the two nuts (3) that secure the seat airbag to the side of the seat back frame. 7. Grasp the outboard side of the seat back trim cover and pull the trim cover and cushion over the top of the seat back frame. This will allow room to remove the seat airbag without damaging the trim cover or the cushion. 8. Working between the seat back trim cover and the seat back frame carefully disengage the two seat airbag studs from the nylon pouch and slide the airbag out of the pouch. Be careful not to tear or damage the nylon pouch or the trim cover. Installation INSTALLATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag-Driver > Page 7730 CAUTION: The seat airbag (1) must be installed into the nylon pouch integral to the front seat back trim cover before the airbag or the trim cover are installed on the front seat back frame. Failure to do so will adversely affect the function of the seat airbag system. 1. Carefully slide the seat airbag into the nylon pouch integral to the outboard side of the front seat back trim cover and engage the two airbag studs through the holes provided in the pouch. Be careful not to tear or damage the nylon pouch or the trim cover. 2. Position the seat airbag and trim cover as a unit to the outboard side of the seat back frame (2) and insert the studs through the mounting holes in the frame. 3. Install and tighten the two nuts (3) that secure the seat airbag to the side of the seat back frame. Tighten the nuts to 10 Nm (89 in. lbs.). 4. Reconnect the seat wire harness (4) connector to the seat airbag inflator. Be certain that the connector latches and lock are fully engaged. CAUTION: Be certain that all of the trim is properly reinstalled on the front seat back frame. Failure to do so will adversely affect the function of the seat airbag system. 5. Reinstall the trim onto the front and back of the front seat back (2). 6. Reinstall the front seat into the vehicle. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. FOR THE SYSTEM TEST, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Supplemental Restraints Verification Test Removal REMOVAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag-Driver > Page 7731 1. Open hood. 2. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the system reserve capacitor to discharge before servicing any airbag components. 3. Remove the driver airbag. 4. With driver airbag removed, pick a corner and push down on the inflator or latch hook mounting plate (1) until the latch hooks (2) push out of the driver airbag cover (3). 5. Starting at a point on the airbag, work your way around the airbag until all the hooks have been released. 6. Remove driver airbag trim cover from driver airbag. Installation INSTALLATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag-Driver > Page 7732 1. Place driver airbag into new driver airbag cover. WARNING: Be careful not to pinch airbag cushion between latch hook mounting plate and cover. 2. Push down on the latch hook mounting plate (1) and guide the latch hooks (2) into the slots on the driver airbag cover (3). 3. Once all the latch hooks have been started, pull the driver airbag cover away from the driver airbag to fully seat the latch hooks. 4. Install the driver airbag. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. FOR THE SYSTEM TEST, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Supplemental Restraints Verification Test Removal REMOVAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag-Driver > Page 7733 NOTE: It is not necessary to remove the knee blocker airbag (1) from the instrument panel (2) all the way. After loosening the two nuts (3) to the instrument panel there should be enough room to unlatch the trim cover (5). 1. Open hood, disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. 2. Remove the two lower knee blocker airbag trim cover screws (4). 3. Reach up behind the knee blocker airbag (1) and remove the two nuts (3) holding the airbag to the instrument panel (2). 4. Pull the knee blocker airbag rearward enough to undo the hook and latch retainers to the airbag trim cover (5). Installation INSTALLATION 1. Slide the airbag trim cover over the hook and latch retainers on the knee blocker airbag (1). 2. Push the airbag forward. 3. Reach up behind the instrument panel and install the two knee blocker airbag retaining nuts. Tighten nuts to 10.5 Nm (93 in. lbs.). 4. Install the two knee blocker airbag cover screws (4). WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. FOR THE SYSTEM TEST, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Supplemental Restraints Verification Test Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag-Driver > Page 7734 Removal REMOVAL 1. Open hood. 2. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. 3. Remove the passenger airbag from the instrument panel. 4. Unhook the trim cover from the passenger airbag by lifting the cover over the hook and latch retainers. Installation INSTALLATION 1. Install the passenger airbag trim cover over the hook and loop retainers on the passenger airbag. 2. Install the passenger airbag in the instrument panel. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. FOR THE SYSTEM TEST, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Supplemental Restraints Verification Test Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Module-Occupant Classification Air Bag Control Module: Locations Module-Occupant Classification Component ID: 158 Component : MODULE-OCCUPANT CLASSIFICATION Connector: Name : MODULE-OCCUPANT CLASSIFICATION C1 Color : BLACK # of pins : 10 Qualifier : (EXCEPT EXPORT) Pin Description Circuit 1 FUSED B(+) (I.O.D.) A417 18RD 2-3-4 CAN B BUS (+) D55 20WT/OR 5 CAN B BUS (-) D54 20WT 6-- 7 DRIVER SEAT POSITION SENSOR VOLTAGER263 20LB/VT 8-9 DRIVER SEAT POSITION SENSOR DATA R261 20LB/WT 10 GROUND Z944 20BK Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Module-Occupant Classification > Page 7739 Connector: Name : MODULE-OCCUPANT CLASSIFICATION C2 Color : BLACK # of pins : 12 Qualifier : (EXCEPT EXPORT) Pin Description Circuit 1 SEAT WEIGHT SENSOR 5 VOLT R701 20LG 2 PASSENGER SEAT POSITION SENSOR VOLTAGE R264 20VT/LB 3 SEAT WEIGHT LEFT FRONT SENSOR SIGNAL R717 20LG/DG 4-- Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Module-Occupant Classification > Page 7740 5 SEAT WEIGHT RIGHT FRONT SENSOR SIGNAL R718 20LB/DG 6-7 SEAT WEIGHT RIGHT REAR SENSOR SIGNAL R706 20LB/OR 8-9 SEAT WEIGHT LEFT REAR SENSOR SIGNALR705 20LG/OR 10 - 11 PASSENGER SEAT POSITION SENSOR DATAR262 20WT/LB 12 SEAT WEIGHT SENSOR GROUND R728 20LB/YL Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Module-Occupant Classification > Page 7741 Air Bag Control Module: Locations Module-Occupant Restraint Controller Component ID: 159 Component : MODULE-OCCUPANT RESTRAINT CONTROLLER Connector: Name : MODULE-OCCUPANT RESTRAINT CONTROLLER C1 (ORC) Color : YELLOW # of pins : 24 Pin Description Circuit 1-2-3 CAN B BUS (+) D55 20WT/OR 4 CAN B BUS (-) D54 20WT/PK 5-6-7-- 8-9 LEFT FRONT IMPACT SENSOR GROUND R81 20LB/WT 10 LEFT FRONT IMPACT SENSOR SIGNAL R79 20LB/VT 11 RIGHT FRONT IMPACT SENSOR GROUND R82 20WT/OR 12 RIGHT FRONT IMPACT SENSOR SIGNAL R80 20VT/LB 13 DRIVER KNEE BLOCKER SQUIB LINE 2 R9 18LB/YL 14 DRIVER KNEE BLOCKER SQUIB LINE 1 R11 18LB/DB 15 - 16 - 17 DRIVER SQUIB 1 LINE 2 R43 18LG/BR 18 DRIVER SQUIB 1 LINE 1 R45 18LG/RD 19 PASSENGER SQUIB 1 LINE 1 R44 18LB/OR 20 PASSENGER SQUIB 1 LINE 2 R42 18LB/BR 21 DRIVER SQUIB 2 LINE 2 R61 18LG/VT 22 DRIVER SQUIB 2 LINE 1 R63 18LG/BK 23 PASSENGER SQUIB 2 LINE 1 R64 18LB/WT 24 PASSENGER SQUIB 2 LINE 2 R62 18LB/VT Component Location - 45 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Module-Occupant Classification > Page 7742 Component Location - 46 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Module-Occupant Classification > Page 7743 Connector: Name : MODULE-OCCUPANT RESTRAINT CONTROLLER C2 (ORC) Color : YELLOW # of pins : 32 Pin Description Circuit 1-2-3-4-5 LEFT CURTAIN SQUIB 1 LINE 2 R1 18LB/WT Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Module-Occupant Classification > Page 7744 6 LEFT CURTAIN SQUIB 1 LINE 1 R3 18LB/OR 7 RIGHT CURTAIN SQUIB 1 LINE 1 R4 18OR/LB 8 RIGHT CURTAIN SQUIB 1 LINE 2 R2 18WT/LB 9 DRIVER SEAT BELT TENSIONER LINE 2 R53 18LG/YL 10 DRIVER SEAT BELT TENSIONER LINE 1 R55 18LG/DG 11 PASSENGER SEAT BELT TENSIONER LINE 1R56 18LB/DG 12 PASSENGER SEAT BELT TENSIONER LINE 2R54 18LB/YL 13 - 14 - 15 - 16 - - 17 FUSED IGNITION SWITCH OUTPUT (RUN-START) F200 20PK/LB 18 FUSED IGNITION SWITCH OUTPUT (RUN) F100 20DG/YL 19 - 20 GROUND Z944 18BK/LG 21 PASSENGER HALL EFFECT (-) R272 20LB/VT 22 - 23 - 24 PASSENGER HALL EFFECT (+) R274 20LB/WT 25 - 26 - 27 RIGHT SIDE IMPACT SENSOR 1 SIGNAL R14 20TN/LG 28 RIGHT SIDE IMPACT SENSOR 1 GROUND R16 20BR/LG 29 LEFT SIDE IMPACT SENSOR 1 GROUND R15 20LG/BR 30 LEFT SIDE IMPACT SENSOR 1 SIGNAL R13 20LG/TN 31 - 32 - Component Location - 45 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Module-Occupant Classification > Page 7745 Component Location - 46 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Module-Occupant Classification Air Bag Control Module: Diagrams Module-Occupant Classification Component ID: 158 Component : MODULE-OCCUPANT CLASSIFICATION Connector: Name : MODULE-OCCUPANT CLASSIFICATION C1 Color : BLACK # of pins : 10 Qualifier : (EXCEPT EXPORT) Pin Description Circuit 1 FUSED B(+) (I.O.D.) A417 18RD 2-3-4 CAN B BUS (+) D55 20WT/OR 5 CAN B BUS (-) D54 20WT 6-- 7 DRIVER SEAT POSITION SENSOR VOLTAGER263 20LB/VT 8-9 DRIVER SEAT POSITION SENSOR DATA R261 20LB/WT 10 GROUND Z944 20BK Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Module-Occupant Classification > Page 7748 Connector: Name : MODULE-OCCUPANT CLASSIFICATION C2 Color : BLACK # of pins : 12 Qualifier : (EXCEPT EXPORT) Pin Description Circuit 1 SEAT WEIGHT SENSOR 5 VOLT R701 20LG 2 PASSENGER SEAT POSITION SENSOR VOLTAGE R264 20VT/LB 3 SEAT WEIGHT LEFT FRONT SENSOR SIGNAL R717 20LG/DG 4-- Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Module-Occupant Classification > Page 7749 5 SEAT WEIGHT RIGHT FRONT SENSOR SIGNAL R718 20LB/DG 6-7 SEAT WEIGHT RIGHT REAR SENSOR SIGNAL R706 20LB/OR 8-9 SEAT WEIGHT LEFT REAR SENSOR SIGNALR705 20LG/OR 10 - 11 PASSENGER SEAT POSITION SENSOR DATAR262 20WT/LB 12 SEAT WEIGHT SENSOR GROUND R728 20LB/YL Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Module-Occupant Classification > Page 7750 Air Bag Control Module: Diagrams Module-Occupant Restraint Controller Component ID: 159 Component : MODULE-OCCUPANT RESTRAINT CONTROLLER Connector: Name : MODULE-OCCUPANT RESTRAINT CONTROLLER C1 (ORC) Color : YELLOW # of pins : 24 Pin Description Circuit 1-2-3 CAN B BUS (+) D55 20WT/OR 4 CAN B BUS (-) D54 20WT/PK 5-6-7-- 8-9 LEFT FRONT IMPACT SENSOR GROUND R81 20LB/WT 10 LEFT FRONT IMPACT SENSOR SIGNAL R79 20LB/VT 11 RIGHT FRONT IMPACT SENSOR GROUND R82 20WT/OR 12 RIGHT FRONT IMPACT SENSOR SIGNAL R80 20VT/LB 13 DRIVER KNEE BLOCKER SQUIB LINE 2 R9 18LB/YL 14 DRIVER KNEE BLOCKER SQUIB LINE 1 R11 18LB/DB 15 - 16 - 17 DRIVER SQUIB 1 LINE 2 R43 18LG/BR 18 DRIVER SQUIB 1 LINE 1 R45 18LG/RD 19 PASSENGER SQUIB 1 LINE 1 R44 18LB/OR 20 PASSENGER SQUIB 1 LINE 2 R42 18LB/BR 21 DRIVER SQUIB 2 LINE 2 R61 18LG/VT 22 DRIVER SQUIB 2 LINE 1 R63 18LG/BK 23 PASSENGER SQUIB 2 LINE 1 R64 18LB/WT 24 PASSENGER SQUIB 2 LINE 2 R62 18LB/VT Component Location - 45 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Module-Occupant Classification > Page 7751 Component Location - 46 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Module-Occupant Classification > Page 7752 Connector: Name : MODULE-OCCUPANT RESTRAINT CONTROLLER C2 (ORC) Color : YELLOW # of pins : 32 Pin Description Circuit 1-2-3-4-5 LEFT CURTAIN SQUIB 1 LINE 2 R1 18LB/WT Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Module-Occupant Classification > Page 7753 6 LEFT CURTAIN SQUIB 1 LINE 1 R3 18LB/OR 7 RIGHT CURTAIN SQUIB 1 LINE 1 R4 18OR/LB 8 RIGHT CURTAIN SQUIB 1 LINE 2 R2 18WT/LB 9 DRIVER SEAT BELT TENSIONER LINE 2 R53 18LG/YL 10 DRIVER SEAT BELT TENSIONER LINE 1 R55 18LG/DG 11 PASSENGER SEAT BELT TENSIONER LINE 1R56 18LB/DG 12 PASSENGER SEAT BELT TENSIONER LINE 2R54 18LB/YL 13 - 14 - 15 - 16 - - 17 FUSED IGNITION SWITCH OUTPUT (RUN-START) F200 20PK/LB 18 FUSED IGNITION SWITCH OUTPUT (RUN) F100 20DG/YL 19 - 20 GROUND Z944 18BK/LG 21 PASSENGER HALL EFFECT (-) R272 20LB/VT 22 - 23 - 24 PASSENGER HALL EFFECT (+) R274 20LB/WT 25 - 26 - 27 RIGHT SIDE IMPACT SENSOR 1 SIGNAL R14 20TN/LG 28 RIGHT SIDE IMPACT SENSOR 1 GROUND R16 20BR/LG 29 LEFT SIDE IMPACT SENSOR 1 GROUND R15 20LG/BR 30 LEFT SIDE IMPACT SENSOR 1 SIGNAL R13 20LG/TN 31 - 32 - Component Location - 45 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Module-Occupant Classification > Page 7754 Component Location - 46 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Description and Operation > Description Air Bag Control Module: Description and Operation Description DESCRIPTION The Occupant Restraint Controller (ORC) (4) is sometimes referred to as the Airbag Control Module (ACM). The ORC is mounted on the tunnel floor pan in front of the transmission floor shifter. The Occupant Restraint Controller (ORC) is secured with three nuts to a stamped steel mounting bracket welded onto the top of the floor panel transmission tunnel beneath the instrument panel floor console. Concealed within a hollow in the center of the die cast aluminum ORC housing is the electronic circuitry of the ORC which includes a microprocessor, an electronic impact sensor, an electronic safing sensor, and an energy storage capacitor. A stamped metal cover plate is secured to the bottom of the ORC housing with four screws to enclose and protect the internal electronic circuitry and components. An arrow printed on the label on the top of the ORC housing provides a visual verification of the proper orientation of the unit, and should always be pointed toward the front of the vehicle. The ORC housing has integral mounting flanges on three of the four corners. Two electrical connectors exit the rearward facing side of the ORC housing. These connect the ORC to the vehicle electrical system, one from the instrument panel wire harness and the second from the body wire harness. The impact sensor and safing sensor internal to the ORC are calibrated for the specific vehicle, and are only serviced as a unit with the ORC. In addition, there are unique versions of the ORC for vehicles with or without the optional side airbags. The ORC cannot be repaired or adjusted and, if damaged or ineffective, it must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Description and Operation > Description > Page 7757 Air Bag Control Module: Description and Operation Operation OPERATION The microprocessor in the Occupant Restraint Controller (ORC), sometimes referred to as the Airbag Control Module (ACM), contains the supplemental restraint system logic circuits and controls all of the supplemental restraint system components. The ORC uses On-Board Diagnostics (OBD) and can communicate with other electronic modules in the vehicle as well as with the diagnostic scan tool using the Controller Area Network (CAN) data bus. This method of communication is used for control of the airbag indicator in the Electromechanical Instrument Cluster (EMIC) sometimes referred to as the Cab Compartment Node (CCN), and for supplemental restraint system diagnosis and testing through the 16-way data link connector located on the driver side lower edge of the instrument panel. The ORC microprocessor continuously monitors all of the supplemental restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets an active and stored Diagnostic Trouble Code (DTC) and sends electronic messages to the EMIC/CCN over the CAN data bus to turn ON the airbag indicator. An active fault only remains for the duration of the fault, or in some cases for the duration of the current ignition switch cycle, while a stored fault causes a DTC to be stored in memory by the ORC. For some DTC's, if a fault does not recur for a number of ignition cycles, the ORC will automatically erase the stored DTC. For other internal faults, the stored DTC is latched forever. On vehicles equipped with the Occupant Classification System (OCS), the ORC communicates with the Occupant Classification Module (OCM) over the CAN data bus. The ORC will internally disable the passenger airbag and seat belt tensioner deployment circuits if the OCM detects that the passenger front seat is unoccupied or that it is occupied by a load that is inappropriate for an airbag deployment. The ORC also provides a control output to the passenger airbag ON/OFF indicator through the passenger airbag indicator driver circuit. The OCM notifies the ORC when it has detected a monitored system fault and stored a DTC in its memory for any ineffective OCS component or circuit, then the ORC sets a DTC and controls the airbag indicator operation accordingly. The ORC receives battery current through two circuits; an ignition switch output (run) circuit and an ignition switch output (run-start) circuit. The ORC receives ground through a ground circuit of the instrument panel wire harness. These connections allow the ORC to be operational whenever the ignition switch is in the START or ON positions. The ORC also contains an energy-storage capacitor. When the ignition switch is in the START or ON positions, this capacitor is continually being charged with enough electrical energy to deploy the supplemental restraint components for up to one second following a battery disconnect or failure. The purpose of the capacitor is to provide backup supplemental restraint system protection in case there is a loss of battery current supply to the ORC during an impact. Two sensors are contained within the ORC, an electronic impact sensor and a safing sensor. The ORC also monitors inputs from two remote front impact sensors located on the back of the right and left vertical members of the radiator support near the front of the vehicle. The electronic impact sensors are accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. On vehicles equipped with optional side airbags, the ORC also monitors inputs from an internal rollover sensor and four additional remote impact sensors located on the left and right inner B-pillars and C-pillars to control deployment of the side airbag units. The safing sensor is an electronic accelerometer sensor within the ORC that provides an additional logic input to the ORC microprocessor. The safing sensor is used to verify the need for a supplemental restraint deployment by detecting impact energy of a lesser magnitude than that of the primary electronic impact sensors, and must exceed a safing threshold in order for the airbags to deploy. Vehicles equipped with optional side airbags, feature a second safing sensor within the ORC to provide confirmation to the ORC microprocessor of side impact forces. This second safing sensor is a bi-directional unit that detects impact forces from either side of the vehicle. Pre-programmed decision algorithms in the ORC microprocessor determine when the deceleration rate as signaled by the impact sensors and the safing sensors indicate an impact that is severe enough to require supplemental restraint system protection and, based upon the severity of the monitored impact, determines the level of front airbag deployment force required for each front seating position. When the programmed conditions are met, the ORC sends the proper electrical signals to deploy the dual multistage front airbags at the programmed force levels, the front seat belt tensioners and, if the vehicle is so equipped, either side airbag unit. For vehicles equipped with the OCS, the passenger front airbag and seat belt tensioner will be deployed by the ORC only if enabled by the OCM messages (passenger airbag ON/OFF indicator OFF) at the time of the impact. To diagnose the ORC or the electronic controls and communication related to ORC operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal Air Bag Control Module: Service and Repair Removal REMOVAL 1. Open hood. 2. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. 3. Remove the floor shifter bezel (1). 4. It is necessary to lift up but not remove on the jute covered panel (1) covering the ORC (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal > Page 7760 5. Remove the ORC mounting nuts (2). 6. Disconnect the two ORC connectors (4). 7. Remove ORC (3) from vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal > Page 7761 Air Bag Control Module: Service and Repair Installation INSTALLATION NOTE: Make sure to leave the ORC covering panel (1) is in place. Failure to do so may result in false ORC DTC's. The covering prevents the shifter cables from smacking on the top of the ORC and possibly setting a false code. 1. Make sure to lift up on the ORC covering panel to insert the ORC. 2. Connect the two ORC connectors (4) and ensure that the connectors are engaged. 3. Position ORC (arrow pointing forward) on the console floor bracket and mounting studs (1). 4. Install the three ORC retaining nuts (2) and tighten to 9 Nm (79.5 in. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal > Page 7762 5. Install floor shifter bezel (1). WARNING: Do not connect the battery negative cable. Personal injury or death may result if the system test is not performed first. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations Clockspring Assembly / Spiral Cable: Locations Component ID: 162 Component : MODULE-STEERING CONTROL Connector: Name : MODULE-STEERING CONTROL C1 Color : WHITE # of pins : 4 Pin Description Circuit 1 GROUND Z937 20BK/YL Pin Description Circuit 1 GROUND Z936 20BK/LB 2 FUSED B(+) (I.O.D.) A411 20RD/LG 3 LIN BUS D506 20WT/DG 4 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY Component Location - 28 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 7766 Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 7767 Connector: Name : MODULE-STEERING CONTROL C2 Color : WHITE # of pins : 6 Pin Description Circuit 1 RADIO CONTROL MUX X20 20GY/WT 2 RADIO CONTROL RETURN Y13 20DG/RD 3 HORN SWITCH SENSE X3 20DG/VT 4 S/C SIGNAL 2 V72 20OR/VT 5 S/C SWITCH GROUND V937 20VT/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 7768 6 S/C SIGNAL 1 V71 20VT/OR Component Location - 28 Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 7769 Connector: Name : MODULE-STEERING CONTROL C4 Color : WHITE # of pins : 4 Pin Description Circuit 1 DRIVER SQUIB 2 LINE 1 R63 18LG/BK 2 DRIVER SQUIB 2 LINE 2 R61 18LG/VT 3 DRIVER SQUIB 1 LINE 1 R45 18LG/RD 4 DRIVER SQUIB 1 LINE 2 R43 18LG/BR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 7770 Component Location - 28 Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 7771 Connector: Name : MODULE-STEERING CONTROL C5 Color : WHITE # of pins : 6 Pin Description Circuit 1 RADIO CONTROL MUX X20 20GY Pin Description Circuit 1 RADIO CONTROL MUX X20 20GY 2 RADIO CONTROL RETURN Y13 20BK Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 7772 2 RADIO CONTROL RETURN Y13 20BK 3 HORN SWITCH SENSE X3 20DB 4 S/C SIGNAL 2 V72 20PK 5 S/C SIGNAL 1 V71 20VT 6 S/C SWITCH GROUND V937 20YL Component Location - 28 Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 7773 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 7774 Clockspring Assembly / Spiral Cable: Diagrams Component ID: 162 Component : MODULE-STEERING CONTROL Connector: Name : MODULE-STEERING CONTROL C1 Color : WHITE # of pins : 4 Pin Description Circuit 1 GROUND Z937 20BK/YL Pin Description Circuit 1 GROUND Z936 20BK/LB 2 FUSED B(+) (I.O.D.) A411 20RD/LG 3 LIN BUS D506 20WT/DG 4 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY Component Location - 28 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 7775 Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 7776 Connector: Name : MODULE-STEERING CONTROL C2 Color : WHITE # of pins : 6 Pin Description Circuit 1 RADIO CONTROL MUX X20 20GY/WT 2 RADIO CONTROL RETURN Y13 20DG/RD 3 HORN SWITCH SENSE X3 20DG/VT 4 S/C SIGNAL 2 V72 20OR/VT 5 S/C SWITCH GROUND V937 20VT/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 7777 6 S/C SIGNAL 1 V71 20VT/OR Component Location - 28 Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 7778 Connector: Name : MODULE-STEERING CONTROL C4 Color : WHITE # of pins : 4 Pin Description Circuit 1 DRIVER SQUIB 2 LINE 1 R63 18LG/BK 2 DRIVER SQUIB 2 LINE 2 R61 18LG/VT 3 DRIVER SQUIB 1 LINE 1 R45 18LG/RD 4 DRIVER SQUIB 1 LINE 2 R43 18LG/BR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 7779 Component Location - 28 Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 7780 Connector: Name : MODULE-STEERING CONTROL C5 Color : WHITE # of pins : 6 Pin Description Circuit 1 RADIO CONTROL MUX X20 20GY Pin Description Circuit 1 RADIO CONTROL MUX X20 20GY 2 RADIO CONTROL RETURN Y13 20BK Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 7781 2 RADIO CONTROL RETURN Y13 20BK 3 HORN SWITCH SENSE X3 20DB 4 S/C SIGNAL 2 V72 20PK 5 S/C SIGNAL 1 V71 20VT 6 S/C SWITCH GROUND V937 20YL Component Location - 28 Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 7782 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Description and Operation > Description Clockspring Assembly / Spiral Cable: Description and Operation Description DESCRIPTION The clockspring (3) for this vehicle is secured near the top of the steering column below the steering wheel. The clockspring also includes an integral, internal turn signal cancel cam and a Steering Angle Sensor (SAS) that are both serviced as a unit with the clockspring. The clockspring also supports the left (lighting) multi-function switch (1), the Steering Control Module (SCM) internal to the left multi-function switch housing (2), and the right (wiper) multi-function switch (6). Each of these switches and the jumper wire harness (5) between the two multi-function switches can be separated from and are serviced individually from the clockspring. The clockspring case includes integral tabs for mounting the unit with three screws to the steering column lock housing as well as integral provisions for mounting and supporting both multi-function switches. The multi-function switches are each secured to the clockspring with a single screw (7). The SAS within the clockspring includes an electronic circuit board and a microprocessor, which allows it to communicate with other electronic modules in the vehicle over the Controller Area Network (CAN) data bus. The SAS circuitry, the clockspring, and the turn signal cancel cam are all contained within a flat, molded plastic case. The clockspring case includes three connector receptacles that face toward the instrument panel. Within the plastic case is a spool-like molded plastic rotor with a large exposed hub. The upper surface of the rotor hub has a large center hole, two short pigtail wires with connectors, and a connector receptacle that faces toward the steering wheel. The lower surface of the rotor has an integral dowel that also faces toward the steering wheel. Wound around the rotor spool within the case is a long ribbon-like tape that consists of several thin copper wire leads sandwiched between two thin plastic membranes. The outer end of the tape terminates at two of the connector receptacles that face the instrument panel, while the inner end of the tape terminates at the pigtail wires and connector receptacle on the hub of the clockspring rotor that face the steering wheel. The outer surface of the rotor hub rim within the clockspring case also has the integral lobes of the turn signal cancel cam. The service replacement clockspring is shipped pre-centered and with a molded plastic locking pin (4) installed. The locking pin secures the centered clockspring rotor to the clockspring case during shipment and handling, but must be removed after the clockspring is installed on the steering column and the steering wheel is installed. The clockspring cannot be repaired. If the clockspring is ineffective, damaged, or if the driver airbag has been deployed, the clockspring/turn signal cancel cam/SAS unit must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Description and Operation > Description > Page 7785 Clockspring Assembly / Spiral Cable: Description and Operation Operation OPERATION The clockspring is a mechanical electrical circuit component that is used to provide continuous electrical continuity between the fixed instrument panel wire harness and certain electrical components mounted on or in the rotating steering wheel. On this vehicle the rotating electrical components include the driver airbag, the horn switch, the speed control switch, and the remote radio switches, if the vehicle is so equipped. The clockspring is positioned and secured near the top of the steering column. The fixed connector receptacles on the back of the fixed clockspring case connect the clockspring to the vehicle electrical system through three take outs with connectors from the instrument panel wire harness. The turn signal cancel cam is integral to the rim of the clockspring rotor hub within the clockspring case so it also moves with the rotation of the steering wheel. Two short, black-sleeved pigtail wires on the upper surface of the clockspring rotor connect the clockspring to the driver airbag, while a steering wheel wire harness connected to the connector receptacle on the upper surface of the clockspring rotor complete circuits to the horn switch, the speed control switch and, if the vehicle is so equipped, to the optional remote radio switches on the steering wheel. The third connector receptacle is dedicated to the inputs and outputs of the Steering Angle Sensor (SAS) internal to the clockspring case. Like the clockspring in a timepiece, the clockspring tape has travel limits and can be damaged by being wound too tightly during full stop-to-stop steering wheel rotation. To prevent this from occurring, the clockspring is centered when it is installed on the steering column. Centering the clockspring indexes the clockspring tape to the movable steering components so that the tape can operate within its designed travel limits. However, if the steering wheel is removed from the steering column, if the clockspring is removed from the steering column, or if the steering shaft is disconnected from the steering gear, the clockspring spool can change position relative to the other steering components. The clockspring must be re-centered following completion of this service or the tape may be damaged. Service replacement clocksprings are shipped pre-centered and with a plastic locking pin installed. This locking pin should not be removed until the steering wheel has been installed on the steering column. If the locking pin is removed before the steering wheel is installed on a steering column, the clockspring centering procedure must be performed. Proper clockspring installation may be confirmed by viewing the SAS data using a diagnostic scan tool. to diagnose the SAS or the electronic controls and communication related to ESP or SRS operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Description and Operation > Page 7786 Clockspring Assembly / Spiral Cable: Adjustments CLOCKSPRING CENTERING WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, occupant classification system, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: A service replacement clockspring is shipped with the clockspring pre-centered and with a molded plastic locking pin installed. This locking pin should not be removed until the steering wheel has been installed on the steering column. If the locking pin is removed before the steering wheel is installed, the clockspring centering procedure must be performed. When a clockspring is installed into a vehicle without properly centering and locking the entire steering system, the Steering Angle Sensor (SAS) data does not agree with the true position of the steering system and causes the ESP system to shut down. This may also damage the clockspring without any immediate malfunction. Unlike some other DaimlerChrysler vehicles, this SAS never requires calibration. Determining if the clockspring/SAS is centered is also possible electrically using the diagnostic scan tool. Steering wheel position is displayed as ANGLE with a range of up to 900 degrees. Refer to the appropriate menu item on the diagnostic scan tool. Before starting this procedure, be certain to turn the steering wheel until the front wheels are in the straight-ahead position and that the entire steering system is locked or inhibited from rotation. The clockspring may be centered and the rotor may be rotated freely once the steering wheel has been removed. 1. Place the front wheels in the straight-ahead position and inhibit the steering column shaft from rotation. 2. Remove the steering wheel from the steering shaft. 3. Rotate the clockspring rotor (1) clockwise to the end of its travel. Do not apply excessive torque. 4. From the end of the clockwise travel, rotate the rotor about two and one-half turns counterclockwise. Turn the rotor slightly clockwise or counterclockwise as necessary so that the clockspring airbag pigtail wires (3) and connector receptacle are at the top and the dowel pin (5) is at the bottom. 5. The clockspring is now centered. Secure the clockspring rotor to the clockspring case using a locking pin (2) or some similar device to maintain clockspring centering until the steering wheel is reinstalled on the steering column. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Removal Clockspring Assembly / Spiral Cable: Service and Repair Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, occupant classification system, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: A service replacement clockspring is shipped with the clockspring pre-centered and with a molded plastic locking pin installed. This locking pin should not be removed until the steering wheel has been installed on the steering column. If the locking pin is removed before the steering wheel is installed, the clockspring centering procedure must be performed. When a clockspring is installed into a vehicle without properly centering and locking the entire steering system, the Steering Angle Sensor (SAS) data does not agree with the true position of the steering system and causes the ESP system to shut down. This may also damage the clockspring without any immediate malfunction. Unlike some other DaimlerChrysler vehicles, this SAS never requires calibration. Determining if the clockspring/SAS is centered is also possible electrically using the diagnostic scan tool. Steering wheel position is displayed as ANGLE with a range of up to 900 degrees. Refer to the appropriate menu item on the diagnostic scan tool. Before starting this procedure, be certain to turn the steering wheel until the front wheels are in the straight-ahead position and that the entire steering system is locked or inhibited from rotation. 1. Place the front wheels in the straight ahead position and inhibit the steering column shaft from rotation. 2. Disconnect and isolate the battery negative cable. 3. Remove the steering wheel from the steering shaft. 4. If the removed clockspring is to be reused, be certain to secure the clockspring rotor to the clockspring case to maintain clockspring centering until the steering wheel is reinstalled on the steering column. If clockspring centering is not maintained, the clockspring must be centered again before the steering wheel is reinstalled. 5. Move the steering column to the fully lowered position and leave the tilt release lever in the released (down) position. 6. Remove the upper and lower shrouds from the steering column. 7. Remove the right multi-function switch (3) from the clockspring (4). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Removal > Page 7789 8. Remove the left multi-function switch (5) from the clockspring. 9. Remove the three screws (1) that secure the clockspring to the steering column lock housing (2). 10. Pull the clockspring (1) away from the steering column lock housing far enough to access and disconnect the three instrument panel wire harness connectors (2) from the receptacles on the back of the clockspring case. 11. Remove the clockspring from the steering column. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Removal > Page 7790 Clockspring Assembly / Spiral Cable: Service and Repair Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, occupant classification system, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: A service replacement clockspring is shipped with the clockspring pre-centered and with a molded plastic locking pin installed. This locking pin should not be removed until the steering wheel has been installed on the steering column. If the locking pin is removed before the steering wheel is installed, the clockspring centering procedure must be performed. When a clockspring is installed into a vehicle without properly centering and locking the entire steering system, the Steering Angle Sensor (SAS) data does not agree with the true position of the steering system and causes the ESP system to shut down. This may also damage the clockspring without any immediate malfunction. Unlike some other DaimlerChrysler vehicles, this SAS never requires calibration. Determining if the clockspring/SAS is centered is also possible electrically using the diagnostic scan tool. Steering wheel position is displayed as ANGLE with a range of up to 900 degrees. Refer to the appropriate menu item on the diagnostic scan tool. Before starting this procedure, be certain to turn the steering wheel until the front wheels are in the straight-ahead position and that the entire steering system is locked or inhibited from rotation. 1. If a new clockspring (1) is being installed, transfer the multifunction switch jumper harness from the old clockspring or position a new jumper harness onto the new clockspring. 2. Carefully slide the clockspring down over the steering column upper shaft far enough to reconnect the three instrument panel wire harness connectors (2) to the receptacles on the back of the clockspring case. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Removal > Page 7791 3. Position the clockspring (4) onto the steering column lock housing (2). 4. Install and tighten the three screws (1) that secure the clockspring to the lock housing in the following sequence: lower right, upper left, upper right. Tighten the screws to 3 Nm (27 in. lbs.). NOTE: Use of an improper sequence when tightening the clockspring mounting screws may result in an audible ticking noise as the steering wheel is rotated. 5. Reinstall the left multi-function switch (5) onto the clockspring. 6. Reinstall the right multi-function switch (3) onto the clockspring. 7. Reinstall the upper and lower shrouds onto the steering column. 8. Move the steering column back to the fully raised position and move the tilt release lever back to the locked (up) position. 9. Reinstall the steering wheel onto the steering column. 10. Remove the plastic locking pin that secures the clockspring rotor to the clockspring case to maintain clockspring centering. WARNING: Do not connect the battery negative cable. Serious or fatal injury may result if the system test is not performed first. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left Impact Sensor: Locations Sensor-Front Impact-Left Component ID: 293 Component : SENSOR-FRONT IMPACT-LEFT Connector: Name : SENSOR-FRONT IMPACT-LEFT Color : YELLOW # of pins : 2 Pin Description Circuit 1 LEFT FRONT IMPACT SENSOR GROUND R81 20LB/WT 2 LEFT FRONT IMPACT SENSOR SIGNAL R79 20LB/VT Component Location - 7 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 7796 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 7797 Impact Sensor: Locations Sensor-Side Impact-Left 1 Component ID: 312 Component : SENSOR-SIDE IMPACT-LEFT 1 Connector: Name : SENSOR-SIDE IMPACT-LEFT 1 Color : YELLOW # of pins : 4 Pin Description Circuit 1 LEFT SIDE IMPACT SENSOR 1 SIGNAL R13 20LG/TN 2 LEFT SIDE IMPACT SENSOR 1 GROUND R15 20LG/BR 3 LEFT SIDE IMPACT SENSOR 2 GROUND R19 20LG/WT 4 LEFT SIDE IMPACT SENSOR 2 SIGNAL R17 20LG/LB Component Location - 48 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 7798 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 7799 Impact Sensor: Locations Sensor-Side Impact-Left 2 Component ID: 313 Component : SENSOR-SIDE IMPACT-LEFT 2 Connector: Name : SENSOR-SIDE IMPACT-LEFT 2 Color : YELLOW # of pins : 2 Pin Description Circuit 1 LEFT SIDE IMPACT SENSOR 2 GROUND R19 20LG/WT 2 LEFT SIDE IMPACT SENSOR 2 SIGNAL R17 20LG/LB Component Location - 60 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 7800 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 7801 Impact Sensor: Locations Sensor-Side Impact-Right 1 Component ID: 314 Component : SENSOR-SIDE IMPACT-RIGHT 1 Connector: Name : SENSOR-SIDE IMPACT-RIGHT 1 Color : YELLOW # of pins : 4 Pin Description Circuit 1 RIGHT SIDE IMPACT SENSOR 1 SIGNAL R14 20TN/LG 2 RIGHT SIDE IMPACT SENSOR 1 GROUND R16 20BR/LG 3 RIGHT SIDE IMPACT SENSOR 2 GROUND R20 20WT/LG 4 RIGHT SIDE IMPACT SENSOR 2 SIGNAL R18 20LB/LG Component Location - 50 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 7802 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 7803 Impact Sensor: Locations Sensor-Side Impact-Right 2 Component ID: 315 Component : SENSOR-SIDE IMPACT-RIGHT 2 Connector: Name : SENSOR-SIDE IMPACT-RIGHT 2 Color : YELLOW # of pins : 2 Pin Description Circuit 1 RIGHT SIDE IMPACT SENSOR 2 GROUND R20 20WT/LG 2 RIGHT SIDE IMPACT SENSOR 2 SIGNAL R18 20LB/LG Component Location - 63 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 7804 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left Impact Sensor: Diagrams Sensor-Front Impact-Left Component ID: 293 Component : SENSOR-FRONT IMPACT-LEFT Connector: Name : SENSOR-FRONT IMPACT-LEFT Color : YELLOW # of pins : 2 Pin Description Circuit 1 LEFT FRONT IMPACT SENSOR GROUND R81 20LB/WT 2 LEFT FRONT IMPACT SENSOR SIGNAL R79 20LB/VT Component Location - 7 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 7807 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 7808 Impact Sensor: Diagrams Sensor-Side Impact-Left 1 Component ID: 312 Component : SENSOR-SIDE IMPACT-LEFT 1 Connector: Name : SENSOR-SIDE IMPACT-LEFT 1 Color : YELLOW # of pins : 4 Pin Description Circuit 1 LEFT SIDE IMPACT SENSOR 1 SIGNAL R13 20LG/TN 2 LEFT SIDE IMPACT SENSOR 1 GROUND R15 20LG/BR 3 LEFT SIDE IMPACT SENSOR 2 GROUND R19 20LG/WT 4 LEFT SIDE IMPACT SENSOR 2 SIGNAL R17 20LG/LB Component Location - 48 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 7809 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 7810 Impact Sensor: Diagrams Sensor-Side Impact-Left 2 Component ID: 313 Component : SENSOR-SIDE IMPACT-LEFT 2 Connector: Name : SENSOR-SIDE IMPACT-LEFT 2 Color : YELLOW # of pins : 2 Pin Description Circuit 1 LEFT SIDE IMPACT SENSOR 2 GROUND R19 20LG/WT 2 LEFT SIDE IMPACT SENSOR 2 SIGNAL R17 20LG/LB Component Location - 60 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 7811 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 7812 Impact Sensor: Diagrams Sensor-Side Impact-Right 1 Component ID: 314 Component : SENSOR-SIDE IMPACT-RIGHT 1 Connector: Name : SENSOR-SIDE IMPACT-RIGHT 1 Color : YELLOW # of pins : 4 Pin Description Circuit 1 RIGHT SIDE IMPACT SENSOR 1 SIGNAL R14 20TN/LG 2 RIGHT SIDE IMPACT SENSOR 1 GROUND R16 20BR/LG 3 RIGHT SIDE IMPACT SENSOR 2 GROUND R20 20WT/LG 4 RIGHT SIDE IMPACT SENSOR 2 SIGNAL R18 20LB/LG Component Location - 50 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 7813 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 7814 Impact Sensor: Diagrams Sensor-Side Impact-Right 2 Component ID: 315 Component : SENSOR-SIDE IMPACT-RIGHT 2 Connector: Name : SENSOR-SIDE IMPACT-RIGHT 2 Color : YELLOW # of pins : 2 Pin Description Circuit 1 RIGHT SIDE IMPACT SENSOR 2 GROUND R20 20WT/LG 2 RIGHT SIDE IMPACT SENSOR 2 SIGNAL R18 20LB/LG Component Location - 63 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 7815 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Description and Operation > Front Impact Sensor: Description and Operation Front Description FRONT Two front impact sensors (1) are used on this vehicle, one each for the left and right sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). Each front sensor is secured with a screw to the backs of the right and left vertical members of the radiator support within the engine compartment. The right and left front impact sensors are identical in construction and calibration. A cavity in the center of the molded black plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material that fills the cavity to seal and protect the internal electronic circuitry and components. The front impact sensors are each connected to the vehicle electrical system through the headlamp and dash wire harness. The impact sensors cannot be repaired or adjusted and, if damaged or ineffective, they must be replaced. Operation FRONT The front impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the passive restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through dedicated left and right sensor plus and minus circuits from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor plus circuit. To diagnose the impact sensors or the electronic controls and communication related to front impact sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Description and Operation > Front > Page 7818 Impact Sensor: Description and Operation Side Description SIDE Four side impact sensors (1) are used on this vehicle when it is equipped with the optional side airbags, two each for the left and right sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). Each side sensor is secured with a screw to the right or left B-pillar and C-pillar. The right and left side impact sensors are identical in construction and calibration. A cavity in the center of the molded black plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material fills the cavity to seal and protect the internal electronic circuitry and components. The side impact sensors are each connected to the vehicle electrical system through the body wire harness. The impact sensors cannot be repaired or adjusted and, if damaged or ineffective, they must be replaced. Operation SIDE The side impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the side passive restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through the same left or right sensor plus and minus circuits in a series arrangement from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor plus circuit. To diagnose the impact sensors or the electronic controls and communication related to side impact sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal Impact Sensor: Service and Repair Removal Front FRONT 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the system reserve capacitor to discharge before servicing any airbag components. 2. Remove the screw (4) that secures the right or left front impact sensor (3) to the back of the right or left radiator support vertical member (2). 3. Disconnect the connector (1) from the sensor (3). 4. Remove the right or left front impact sensor from the engine compartment. Side - B-Pillar SIDE - B-PILLAR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal > Page 7821 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the system reserve capacitor to discharge before servicing any airbag components. 2. Remove the B-pillar lower trim panel. 3. Disconnect the harness connector (4) from the sensor (2). 4. Remove the screw (1) retaining the B-pillar side impact sensor (2) 5. Remove the sensor (2) from the vehicle. Side - C-Pillar SIDE - C-PILLAR 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the system reserve capacitor to discharge before servicing any airbag components. 2. Remove the rear quarter panel trim. 3. Remove the screw (4) that secures the side impact sensor (3) to the C-pillar (1). 4. Disconnect the harness connector (2) from the sensor (3). 5. Remove the sensor from the C-pillar. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal > Page 7822 Impact Sensor: Service and Repair Installation Front FRONT 1. Position the right or left front impact sensor (3) into the engine compartment near it mounting area. 2. Connect the harness connector (1) to the sensor. 3. Position the sensor onto the back of the right or left radiator support vertical member (2). NOTE: Be certain that the anti-rotation pin on the back of the sensor is engaged in the lower clearance hole of the radiator support. 4. Install and tighten the screw (4) that secures the sensor (3) to the back of the support vertical member (2). Tighten the screw to 8 Nm (71 in. lbs.). WARNING: Do not connect the battery negative cable. Personal injury or death may result if the system test is not performed first. Side - B-Pillar SIDE - B-PILLAR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal > Page 7823 1. Position the sensor onto the B-pillar and install the mounting screw (1). Tighten the screw to 8 Nm (71 in. lbs.). NOTE: Be certain that the anti-rotation pin on the back of the sensor is engaged in the hole just below the mounting hole in the B-pillar (3). 2. Connect the harness connector (4) to the sensor (2). 3. Install the B-pillar lower trim panel. WARNING: Do not connect the battery negative cable. Personal injury or death may result if the system test is not performed first. Side - C-Pillar SIDE - C-PILLAR 1. Position the side impact sensor near the inner C-pillar. 2. Connect the harness connector (2) to the sensor (3). 3. Position the sensor onto the C-pillar. NOTE: Be certain that the anti-rotation pin on the back of the sensor is engaged in the clearance hole on the C-pillar below the sensor mounting hole. 4. Install screw (4) that secures the sensor (3) to the C-pillar (1). Tighten the screw to 8 Nm (71 in. lbs.). 5. Install the rear quarter panel trim. WARNING: Do not connect the battery negative cable. Personal injury or death may result if the system test is not performed first. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Description and Operation > Description Seat Occupant Classification Module - Air Bag: Description and Operation Description DESCRIPTION The Occupant Classification Module (OCM) (1) is secured to the passenger side outboard front seat track riser. Concealed within a hollow in the center of the molded plastic OCM housing is a microprocessor and the other electronic circuitry of the module. The module housing is sealed to enclose and protect the internal electronic circuitry. The OCM and all of the other components of the Occupant Classification System (OCS) including the passenger side front seat, the seat weight sensors, the passenger or driver seat track position sensor and the seat adjusters, cushion, back, frame, foam, springs, and wiring harness are a factory-calibrated and assembled unit. Any time any one of these components is removed or replaced for any reason, the OCM must be re-calibrated using a diagnostic scan tool, the Occupant Classification Seat Weight special tool 9077, and the Occupant Classification System Verification Test. Refer to the appropriate diagnostic procedures. The OCM cannot be adjusted or repaired and, if damaged or faulty, it must be replaced. The OCM software is flash programmable. A non-calibrated OCM is available for separate service replacement. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Description and Operation > Description > Page 7828 Seat Occupant Classification Module - Air Bag: Description and Operation Operation OPERATION The microprocessor in the Occupant Classification Module (OCM) contains the Occupant Classification System (OCS) logic circuits. The OCM uses On-Board Diagnostics (OBD) and can communicate with other electronic modules in the vehicle as well as with the diagnostic scan tool using the Controller Area Network (CAN) data bus. This method of communication is also used for OCS diagnosis and testing through the 16-way Data Link Connector (DLC) located on the driver side lower edge of the instrument panel. The OCM provides voltage to the four seat weight sensors located on each of the four corners of the passenger side front seat, and to the seat track position sensors located on the passenger and driver front seat tracks. The OCM then monitors return inputs from each of the sensors on dedicated hard wired data communication circuits. The seat weight sensor input allows the OCM to determine whether the passenger front seat is occupied and the relative size of the occupant by providing a weight-sensing reference to the load on the seat. The seat track position sensor provides an additional logic input to the OCM microprocessor that allows it to determine the position of the front seat passenger and driver relative to the front airbags. Pre-programmed decision algorithms and OCS calibration allow the OCM microprocessor to determine when passenger airbag protection is appropriate based upon the seat load as signaled by the seat weight sensors. When the programmed conditions are met, the OCM sends the proper electronic occupant classification messages over the CAN data bus to the Occupant Restraint Controller (ORC), and the ORC enables or disables the deployment circuits for the passenger front supplemental restraints. On vehicles so equipped, the ORC also provides a control output for the passenger airbag on/off indicator in the instrument panel based upon the electronic occupant classification messages it receives from the OCM. The OCM also sends electronic driver and passenger seat track position messages to the ORC over the CAN data bus. The ORC uses the seat track position data as an additional logic input for determining the force level with which to deploy the multistage front airbags. The OCM microprocessor continuously monitors all of the OCS electrical circuits and components to determine the system readiness. If the OCM detects a monitored system fault, it sets an active and stored Diagnostic Trouble Code (DTC) and sends the appropriate electronic messages to the ORC over the CAN data bus. Then the ORC sets a DTC and sends messages to control the airbag indicator operation accordingly. An active fault only remains for the duration of the fault, or in some cases for the duration of the current ignition switch cycle, while a stored fault causes a DTC to be stored in memory by the OCM and the ORC. For some DTC's, if a fault does not recur for a number of ignition cycles, the OCM will automatically erase the stored DTC. For other internal faults, the stored DTC is latched forever. The OCM receives battery current on a fused ignition switch output (run-start) circuit through a fuse in the Junction Block (JB). The OCM receives ground through a ground circuit of the body wire harness. These connections allow the OCM to be operational whenever the ignition switch is in the Start or On positions. To diagnose the OCM and all its inputs, outputs and related circuits, use a diagnostic scan tool and the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Service and Repair > Removal Seat Occupant Classification Module - Air Bag: Service and Repair Removal REMOVAL WARNING: The replacement Occupant Classification Module (OCM) is a non-calibrated unit when first installed. The OCM and all of the other components of the Occupant Classification System (OCS) including the passenger front seat, the seat weight sensors, the passenger or driver seat track position sensor and the seat adjusters, cushion, back, frame, foam, springs, and wiring harness are a factory-calibrated and assembled unit. Any time any one of these components is removed or replaced for any reason, the OCM must be re-calibrated using a diagnostic scan tool, the Occupant Classification Seat Weight special tool 9077, and the Occupant Classification System Verification Test. Refer to the appropriate diagnostic procedures. 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. 2. Reach under the front edge of the passenger side front seat cushion to access and remove the two screws that secure the Occupant Classification Module (OCM) (3) to the underside of the passenger front seat cushion pan. 3. Pull the OCM down far enough to access the module wiring connections (4). 4. Disconnect the two electrical connectors (4) from the OCM (3). 5. Remove the OCM (3) from under the passenger front seat. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Service and Repair > Removal > Page 7831 Seat Occupant Classification Module - Air Bag: Service and Repair Installation INSTALLATION WARNING: A non-calibrated Occupant Classification Module (OCM) is available for separate service replacement. The OCM and all of the other components of the Occupant Classification System (OCS) including the passenger side front seat, the seat weight sensors, the passenger or driver seat track position sensor and the seat adjusters, cushion, back, frame, foam, springs, and wiring harness are a factory-calibrated and assembled unit. Any time any one of these components is removed or replaced for any reason, the OCM must be re-calibrated using a diagnostic scan tool, the Occupant Classification Seat Weight special tool 9077, and the Occupant Classification System Verification Test. Refer to the appropriate diagnostic procedures. 1. Position the Occupant Classification Module (OCM) (3) under the passenger front seat cushion. 2. Connect the two electrical connectors (4) to the OCM (3). 3. Carefully position the OCM to the seat cushion pan. 4. Install the two screws that secure the OCM to the seat cushion pan. WARNING: Do not connect the battery negative cable. Personal injury or death may result if the system test is not performed first. WARNING: Following successful completion of the Airbag System verification test procedure, perform the Occupant Classification System Verification Test using a diagnostic scan tool and the Occupant Classification Seat Weight special tool 9077. Refer to the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Description and Operation > Description Seat Occupant Sensor: Description and Operation Description DESCRIPTION The seat weight sensors are strain gauge-type units. The electronic elements of the sensor are encased within the sensor body (4). Four sensors are used in the Occupant Classification System (OCS). The sensors are located below the seat cushion between the seat adjuster track and the seat adjuster riser at each corner of the passenger side front seat. A threaded mounting stud (2) on each sensor body is secured by a nut to the seat adjuster riser, and two nuts secure each sensor mounting flange (1) to two studs integral to the front and rear of the inboard and outboard passenger side lower seat adjuster tracks. A molded connector receptacle (3) integral to each sensor body is oriented towards the center of the seat and is connected to the vehicle electrical system through a dedicated connector and take out of the passenger seat wire harness beneath the seat cushion. The seat weight sensors cannot be adjusted or repaired and, if faulty or damaged, the entire sensor must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Description and Operation > Description > Page 7836 Seat Occupant Sensor: Description and Operation Operation OPERATION The seat weight sensor units are designed to sense the relative weight of a load applied to the passenger side front seat, which provides a logic input to the microprocessor of the Occupant Classification Module (OCM). When any load is applied to the seat the load is transmitted through the sensor mounting flange to the sensor body (strain gauge) of each sensor, causing a change of electrical resistance through the strain gauge. These changes in resistance within the internal sensor circuitry change the sensor output voltage. Each weight sensor receives a nominal five volts and a clean ground through parallel hard wired circuits from the OCM. The OCM then monitors the output voltage of each sensor on dedicated hard wired data communication circuits. The hard wired circuits between the sensors and the OCM may be diagnosed and tested using conventional diagnostic tools and procedures. However, the most reliable, efficient, and accurate means to diagnose the seat weight sensor inputs to the OCM, and the electronic message communication between the OCM and the Occupant Restraint Controller (ORC) requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Service and Repair > Removal Seat Occupant Sensor: Service and Repair Removal REMOVAL WARNING: To avoid personal injury or death, never strike or drop a seat weight sensor or the passenger side front seat assembly to which the sensors are secured as it can damage the sensors or affect their calibration. The seat weight sensors and the passenger side front seat assembly must be handled with care to avoid damage to the sensors. Do not sit upon or place any loads upon a passenger side front seat while it is removed from its mounts in or outside of the vehicle. If an individual sensor is dropped or damaged, replace the sensor with a new and unused unit. If a seat has been dropped during removal or loaded while removed from its mounts, replace each of the seat weight sensors with new and unused units. Failure to observe this warning could result in an accidental, incomplete, or improper passenger side front supplemental restraint deployment. 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the system reserve capacitor to discharge before servicing any airbag components. 2. Remove the passenger front seat from the vehicle as a unit. CAUTION: Strain gauge alignment tool 9689 (2) must be used to secure the body of the seat weight sensor (1) from any rotation during removal or installation of the nut that secures the sensor stud to the seat adjuster riser. In addition, the sensor fasteners should always be serviced using hand tools ONLY, and not electric or pneumatic power tools. Failure to observe these precautions may result in irreversible sensor damage and require sensor replacement. 3. Remove the passenger front seat riser from the seat. 4. Disconnect each weight sensor electrical connector and install strain gauge alignment tool 9689. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Service and Repair > Removal > Page 7839 5. Insert the fork (1) into weight sensor and seat the support yoke (2) firmly against the weight sensor cage. 6. Remove center stud nut and repeat these steps for each of the four weight sensors. 7. Separate the seat track from the seat risers. 8. Remove the nuts securing the seat weight sensor to the adjuster track and remove the seat weight sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Service and Repair > Removal > Page 7840 Seat Occupant Sensor: Service and Repair Installation INSTALLATION WARNING: To avoid personal injury or death, never strike or drop a seat weight sensor or the passenger side front seat assembly to which the sensors are secured as it can damage the sensors or affect their calibration. The seat weight sensors and the passenger side front seat assembly must be handled with care to avoid damage to the sensors. Do not sit upon or place any loads upon a passenger side front seat while it is removed from its mounts in or outside of the vehicle. If an individual sensor is dropped or damaged, replace the sensor with a new and unused unit. If a seat has been dropped during removal or loaded while removed from its mounts, replace each of the seat weight sensors with new and unused units. Failure to observe this warning could result in an accidental, incomplete, or improper passenger side front supplemental restraint deployment. WARNING: To avoid personal injury or death on vehicles equipped with the Occupant Classification System (OCS), any time the passenger side front seat assembly has been removed or loosened from the vehicle for service of any vehicle component or system the Occupant Classification System Verification Test must be performed using a diagnostic scan tool and the Occupant Classification Seat Weight special tool following reinstallation. Refer to the appropriate diagnostic procedures. Failure to observe this warning could result in an accidental, incomplete, or improper passenger side front supplemental restraint deployment. CAUTION: Strain gauge alignment tool 9689 (2) must be used to secure the body of the seat weight sensor (1) from any rotation during removal or installation of the nut that secures the sensor stud to the seat adjuster riser. In addition, the sensor fasteners should always be serviced using hand tools ONLY, and not electric or pneumatic power tools. Failure to observe these precautions may result in irreversible sensor damage and require sensor replacement. 1. Install the seat weight sensor and install the nuts securing the seat weight sensor to the adjuster track. Tighten nuts to 28 Nm (21 ft. lbs.). 2. Place the seat track onto the seat riser. 3. Install the nut on the center stud and repeat for each of the four weight sensors. CAUTION: Do not tighten the center nut to the seat weight sensors without the use of strain gauge alignment tool 9689. 4. Insert the fork (1) into weight sensor and seat the support yoke (2) firmly against the weight sensor cage. Tighten nut to 45 Nm (33 ft. lbs.). Repeat for all four sensors. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Service and Repair > Removal > Page 7841 5. Connect each weight sensor electrical connector. 6. Reinstall the passenger front seat. WARNING: Do not connect the battery negative cable. Personal injury or death may result if the system test is not performed first. WARNING: Following successful completion of the Airbag System verification test procedure, perform the Occupant Classification System Verification Test using a diagnostic scan tool and the Occupant Classification Seat Weight special tool 9077. Refer to the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Module-Occupant Classification Air Bag Control Module: Locations Module-Occupant Classification Component ID: 158 Component : MODULE-OCCUPANT CLASSIFICATION Connector: Name : MODULE-OCCUPANT CLASSIFICATION C1 Color : BLACK # of pins : 10 Qualifier : (EXCEPT EXPORT) Pin Description Circuit 1 FUSED B(+) (I.O.D.) A417 18RD 2-3-4 CAN B BUS (+) D55 20WT/OR 5 CAN B BUS (-) D54 20WT 6-- 7 DRIVER SEAT POSITION SENSOR VOLTAGER263 20LB/VT 8-9 DRIVER SEAT POSITION SENSOR DATA R261 20LB/WT 10 GROUND Z944 20BK Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Module-Occupant Classification > Page 7847 Connector: Name : MODULE-OCCUPANT CLASSIFICATION C2 Color : BLACK # of pins : 12 Qualifier : (EXCEPT EXPORT) Pin Description Circuit 1 SEAT WEIGHT SENSOR 5 VOLT R701 20LG 2 PASSENGER SEAT POSITION SENSOR VOLTAGE R264 20VT/LB 3 SEAT WEIGHT LEFT FRONT SENSOR SIGNAL R717 20LG/DG 4-- Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Module-Occupant Classification > Page 7848 5 SEAT WEIGHT RIGHT FRONT SENSOR SIGNAL R718 20LB/DG 6-7 SEAT WEIGHT RIGHT REAR SENSOR SIGNAL R706 20LB/OR 8-9 SEAT WEIGHT LEFT REAR SENSOR SIGNALR705 20LG/OR 10 - 11 PASSENGER SEAT POSITION SENSOR DATAR262 20WT/LB 12 SEAT WEIGHT SENSOR GROUND R728 20LB/YL Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Module-Occupant Classification > Page 7849 Air Bag Control Module: Locations Module-Occupant Restraint Controller Component ID: 159 Component : MODULE-OCCUPANT RESTRAINT CONTROLLER Connector: Name : MODULE-OCCUPANT RESTRAINT CONTROLLER C1 (ORC) Color : YELLOW # of pins : 24 Pin Description Circuit 1-2-3 CAN B BUS (+) D55 20WT/OR 4 CAN B BUS (-) D54 20WT/PK 5-6-7-- 8-9 LEFT FRONT IMPACT SENSOR GROUND R81 20LB/WT 10 LEFT FRONT IMPACT SENSOR SIGNAL R79 20LB/VT 11 RIGHT FRONT IMPACT SENSOR GROUND R82 20WT/OR 12 RIGHT FRONT IMPACT SENSOR SIGNAL R80 20VT/LB 13 DRIVER KNEE BLOCKER SQUIB LINE 2 R9 18LB/YL 14 DRIVER KNEE BLOCKER SQUIB LINE 1 R11 18LB/DB 15 - 16 - 17 DRIVER SQUIB 1 LINE 2 R43 18LG/BR 18 DRIVER SQUIB 1 LINE 1 R45 18LG/RD 19 PASSENGER SQUIB 1 LINE 1 R44 18LB/OR 20 PASSENGER SQUIB 1 LINE 2 R42 18LB/BR 21 DRIVER SQUIB 2 LINE 2 R61 18LG/VT 22 DRIVER SQUIB 2 LINE 1 R63 18LG/BK 23 PASSENGER SQUIB 2 LINE 1 R64 18LB/WT 24 PASSENGER SQUIB 2 LINE 2 R62 18LB/VT Component Location - 45 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Module-Occupant Classification > Page 7850 Component Location - 46 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Module-Occupant Classification > Page 7851 Connector: Name : MODULE-OCCUPANT RESTRAINT CONTROLLER C2 (ORC) Color : YELLOW # of pins : 32 Pin Description Circuit 1-2-3-4-5 LEFT CURTAIN SQUIB 1 LINE 2 R1 18LB/WT Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Module-Occupant Classification > Page 7852 6 LEFT CURTAIN SQUIB 1 LINE 1 R3 18LB/OR 7 RIGHT CURTAIN SQUIB 1 LINE 1 R4 18OR/LB 8 RIGHT CURTAIN SQUIB 1 LINE 2 R2 18WT/LB 9 DRIVER SEAT BELT TENSIONER LINE 2 R53 18LG/YL 10 DRIVER SEAT BELT TENSIONER LINE 1 R55 18LG/DG 11 PASSENGER SEAT BELT TENSIONER LINE 1R56 18LB/DG 12 PASSENGER SEAT BELT TENSIONER LINE 2R54 18LB/YL 13 - 14 - 15 - 16 - - 17 FUSED IGNITION SWITCH OUTPUT (RUN-START) F200 20PK/LB 18 FUSED IGNITION SWITCH OUTPUT (RUN) F100 20DG/YL 19 - 20 GROUND Z944 18BK/LG 21 PASSENGER HALL EFFECT (-) R272 20LB/VT 22 - 23 - 24 PASSENGER HALL EFFECT (+) R274 20LB/WT 25 - 26 - 27 RIGHT SIDE IMPACT SENSOR 1 SIGNAL R14 20TN/LG 28 RIGHT SIDE IMPACT SENSOR 1 GROUND R16 20BR/LG 29 LEFT SIDE IMPACT SENSOR 1 GROUND R15 20LG/BR 30 LEFT SIDE IMPACT SENSOR 1 SIGNAL R13 20LG/TN 31 - 32 - Component Location - 45 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Module-Occupant Classification > Page 7853 Component Location - 46 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Module-Occupant Classification Air Bag Control Module: Diagrams Module-Occupant Classification Component ID: 158 Component : MODULE-OCCUPANT CLASSIFICATION Connector: Name : MODULE-OCCUPANT CLASSIFICATION C1 Color : BLACK # of pins : 10 Qualifier : (EXCEPT EXPORT) Pin Description Circuit 1 FUSED B(+) (I.O.D.) A417 18RD 2-3-4 CAN B BUS (+) D55 20WT/OR 5 CAN B BUS (-) D54 20WT 6-- 7 DRIVER SEAT POSITION SENSOR VOLTAGER263 20LB/VT 8-9 DRIVER SEAT POSITION SENSOR DATA R261 20LB/WT 10 GROUND Z944 20BK Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Module-Occupant Classification > Page 7856 Connector: Name : MODULE-OCCUPANT CLASSIFICATION C2 Color : BLACK # of pins : 12 Qualifier : (EXCEPT EXPORT) Pin Description Circuit 1 SEAT WEIGHT SENSOR 5 VOLT R701 20LG 2 PASSENGER SEAT POSITION SENSOR VOLTAGE R264 20VT/LB 3 SEAT WEIGHT LEFT FRONT SENSOR SIGNAL R717 20LG/DG 4-- Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Module-Occupant Classification > Page 7857 5 SEAT WEIGHT RIGHT FRONT SENSOR SIGNAL R718 20LB/DG 6-7 SEAT WEIGHT RIGHT REAR SENSOR SIGNAL R706 20LB/OR 8-9 SEAT WEIGHT LEFT REAR SENSOR SIGNALR705 20LG/OR 10 - 11 PASSENGER SEAT POSITION SENSOR DATAR262 20WT/LB 12 SEAT WEIGHT SENSOR GROUND R728 20LB/YL Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Module-Occupant Classification > Page 7858 Air Bag Control Module: Diagrams Module-Occupant Restraint Controller Component ID: 159 Component : MODULE-OCCUPANT RESTRAINT CONTROLLER Connector: Name : MODULE-OCCUPANT RESTRAINT CONTROLLER C1 (ORC) Color : YELLOW # of pins : 24 Pin Description Circuit 1-2-3 CAN B BUS (+) D55 20WT/OR 4 CAN B BUS (-) D54 20WT/PK 5-6-7-- 8-9 LEFT FRONT IMPACT SENSOR GROUND R81 20LB/WT 10 LEFT FRONT IMPACT SENSOR SIGNAL R79 20LB/VT 11 RIGHT FRONT IMPACT SENSOR GROUND R82 20WT/OR 12 RIGHT FRONT IMPACT SENSOR SIGNAL R80 20VT/LB 13 DRIVER KNEE BLOCKER SQUIB LINE 2 R9 18LB/YL 14 DRIVER KNEE BLOCKER SQUIB LINE 1 R11 18LB/DB 15 - 16 - 17 DRIVER SQUIB 1 LINE 2 R43 18LG/BR 18 DRIVER SQUIB 1 LINE 1 R45 18LG/RD 19 PASSENGER SQUIB 1 LINE 1 R44 18LB/OR 20 PASSENGER SQUIB 1 LINE 2 R42 18LB/BR 21 DRIVER SQUIB 2 LINE 2 R61 18LG/VT 22 DRIVER SQUIB 2 LINE 1 R63 18LG/BK 23 PASSENGER SQUIB 2 LINE 1 R64 18LB/WT 24 PASSENGER SQUIB 2 LINE 2 R62 18LB/VT Component Location - 45 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Module-Occupant Classification > Page 7859 Component Location - 46 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Module-Occupant Classification > Page 7860 Connector: Name : MODULE-OCCUPANT RESTRAINT CONTROLLER C2 (ORC) Color : YELLOW # of pins : 32 Pin Description Circuit 1-2-3-4-5 LEFT CURTAIN SQUIB 1 LINE 2 R1 18LB/WT Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Module-Occupant Classification > Page 7861 6 LEFT CURTAIN SQUIB 1 LINE 1 R3 18LB/OR 7 RIGHT CURTAIN SQUIB 1 LINE 1 R4 18OR/LB 8 RIGHT CURTAIN SQUIB 1 LINE 2 R2 18WT/LB 9 DRIVER SEAT BELT TENSIONER LINE 2 R53 18LG/YL 10 DRIVER SEAT BELT TENSIONER LINE 1 R55 18LG/DG 11 PASSENGER SEAT BELT TENSIONER LINE 1R56 18LB/DG 12 PASSENGER SEAT BELT TENSIONER LINE 2R54 18LB/YL 13 - 14 - 15 - 16 - - 17 FUSED IGNITION SWITCH OUTPUT (RUN-START) F200 20PK/LB 18 FUSED IGNITION SWITCH OUTPUT (RUN) F100 20DG/YL 19 - 20 GROUND Z944 18BK/LG 21 PASSENGER HALL EFFECT (-) R272 20LB/VT 22 - 23 - 24 PASSENGER HALL EFFECT (+) R274 20LB/WT 25 - 26 - 27 RIGHT SIDE IMPACT SENSOR 1 SIGNAL R14 20TN/LG 28 RIGHT SIDE IMPACT SENSOR 1 GROUND R16 20BR/LG 29 LEFT SIDE IMPACT SENSOR 1 GROUND R15 20LG/BR 30 LEFT SIDE IMPACT SENSOR 1 SIGNAL R13 20LG/TN 31 - 32 - Component Location - 45 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Module-Occupant Classification > Page 7862 Component Location - 46 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > Description Air Bag Control Module: Description and Operation Description DESCRIPTION The Occupant Restraint Controller (ORC) (4) is sometimes referred to as the Airbag Control Module (ACM). The ORC is mounted on the tunnel floor pan in front of the transmission floor shifter. The Occupant Restraint Controller (ORC) is secured with three nuts to a stamped steel mounting bracket welded onto the top of the floor panel transmission tunnel beneath the instrument panel floor console. Concealed within a hollow in the center of the die cast aluminum ORC housing is the electronic circuitry of the ORC which includes a microprocessor, an electronic impact sensor, an electronic safing sensor, and an energy storage capacitor. A stamped metal cover plate is secured to the bottom of the ORC housing with four screws to enclose and protect the internal electronic circuitry and components. An arrow printed on the label on the top of the ORC housing provides a visual verification of the proper orientation of the unit, and should always be pointed toward the front of the vehicle. The ORC housing has integral mounting flanges on three of the four corners. Two electrical connectors exit the rearward facing side of the ORC housing. These connect the ORC to the vehicle electrical system, one from the instrument panel wire harness and the second from the body wire harness. The impact sensor and safing sensor internal to the ORC are calibrated for the specific vehicle, and are only serviced as a unit with the ORC. In addition, there are unique versions of the ORC for vehicles with or without the optional side airbags. The ORC cannot be repaired or adjusted and, if damaged or ineffective, it must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > Description > Page 7865 Air Bag Control Module: Description and Operation Operation OPERATION The microprocessor in the Occupant Restraint Controller (ORC), sometimes referred to as the Airbag Control Module (ACM), contains the supplemental restraint system logic circuits and controls all of the supplemental restraint system components. The ORC uses On-Board Diagnostics (OBD) and can communicate with other electronic modules in the vehicle as well as with the diagnostic scan tool using the Controller Area Network (CAN) data bus. This method of communication is used for control of the airbag indicator in the Electromechanical Instrument Cluster (EMIC) sometimes referred to as the Cab Compartment Node (CCN), and for supplemental restraint system diagnosis and testing through the 16-way data link connector located on the driver side lower edge of the instrument panel. The ORC microprocessor continuously monitors all of the supplemental restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets an active and stored Diagnostic Trouble Code (DTC) and sends electronic messages to the EMIC/CCN over the CAN data bus to turn ON the airbag indicator. An active fault only remains for the duration of the fault, or in some cases for the duration of the current ignition switch cycle, while a stored fault causes a DTC to be stored in memory by the ORC. For some DTC's, if a fault does not recur for a number of ignition cycles, the ORC will automatically erase the stored DTC. For other internal faults, the stored DTC is latched forever. On vehicles equipped with the Occupant Classification System (OCS), the ORC communicates with the Occupant Classification Module (OCM) over the CAN data bus. The ORC will internally disable the passenger airbag and seat belt tensioner deployment circuits if the OCM detects that the passenger front seat is unoccupied or that it is occupied by a load that is inappropriate for an airbag deployment. The ORC also provides a control output to the passenger airbag ON/OFF indicator through the passenger airbag indicator driver circuit. The OCM notifies the ORC when it has detected a monitored system fault and stored a DTC in its memory for any ineffective OCS component or circuit, then the ORC sets a DTC and controls the airbag indicator operation accordingly. The ORC receives battery current through two circuits; an ignition switch output (run) circuit and an ignition switch output (run-start) circuit. The ORC receives ground through a ground circuit of the instrument panel wire harness. These connections allow the ORC to be operational whenever the ignition switch is in the START or ON positions. The ORC also contains an energy-storage capacitor. When the ignition switch is in the START or ON positions, this capacitor is continually being charged with enough electrical energy to deploy the supplemental restraint components for up to one second following a battery disconnect or failure. The purpose of the capacitor is to provide backup supplemental restraint system protection in case there is a loss of battery current supply to the ORC during an impact. Two sensors are contained within the ORC, an electronic impact sensor and a safing sensor. The ORC also monitors inputs from two remote front impact sensors located on the back of the right and left vertical members of the radiator support near the front of the vehicle. The electronic impact sensors are accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. On vehicles equipped with optional side airbags, the ORC also monitors inputs from an internal rollover sensor and four additional remote impact sensors located on the left and right inner B-pillars and C-pillars to control deployment of the side airbag units. The safing sensor is an electronic accelerometer sensor within the ORC that provides an additional logic input to the ORC microprocessor. The safing sensor is used to verify the need for a supplemental restraint deployment by detecting impact energy of a lesser magnitude than that of the primary electronic impact sensors, and must exceed a safing threshold in order for the airbags to deploy. Vehicles equipped with optional side airbags, feature a second safing sensor within the ORC to provide confirmation to the ORC microprocessor of side impact forces. This second safing sensor is a bi-directional unit that detects impact forces from either side of the vehicle. Pre-programmed decision algorithms in the ORC microprocessor determine when the deceleration rate as signaled by the impact sensors and the safing sensors indicate an impact that is severe enough to require supplemental restraint system protection and, based upon the severity of the monitored impact, determines the level of front airbag deployment force required for each front seating position. When the programmed conditions are met, the ORC sends the proper electrical signals to deploy the dual multistage front airbags at the programmed force levels, the front seat belt tensioners and, if the vehicle is so equipped, either side airbag unit. For vehicles equipped with the OCS, the passenger front airbag and seat belt tensioner will be deployed by the ORC only if enabled by the OCM messages (passenger airbag ON/OFF indicator OFF) at the time of the impact. To diagnose the ORC or the electronic controls and communication related to ORC operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal Air Bag Control Module: Service and Repair Removal REMOVAL 1. Open hood. 2. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. 3. Remove the floor shifter bezel (1). 4. It is necessary to lift up but not remove on the jute covered panel (1) covering the ORC (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal > Page 7868 5. Remove the ORC mounting nuts (2). 6. Disconnect the two ORC connectors (4). 7. Remove ORC (3) from vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal > Page 7869 Air Bag Control Module: Service and Repair Installation INSTALLATION NOTE: Make sure to leave the ORC covering panel (1) is in place. Failure to do so may result in false ORC DTC's. The covering prevents the shifter cables from smacking on the top of the ORC and possibly setting a false code. 1. Make sure to lift up on the ORC covering panel to insert the ORC. 2. Connect the two ORC connectors (4) and ensure that the connectors are engaged. 3. Position ORC (arrow pointing forward) on the console floor bracket and mounting studs (1). 4. Install the three ORC retaining nuts (2) and tighten to 9 Nm (79.5 in. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal > Page 7870 5. Install floor shifter bezel (1). WARNING: Do not connect the battery negative cable. Personal injury or death may result if the system test is not performed first. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Description and Operation > Description Seat Occupant Classification Module - Air Bag: Description and Operation Description DESCRIPTION The Occupant Classification Module (OCM) (1) is secured to the passenger side outboard front seat track riser. Concealed within a hollow in the center of the molded plastic OCM housing is a microprocessor and the other electronic circuitry of the module. The module housing is sealed to enclose and protect the internal electronic circuitry. The OCM and all of the other components of the Occupant Classification System (OCS) including the passenger side front seat, the seat weight sensors, the passenger or driver seat track position sensor and the seat adjusters, cushion, back, frame, foam, springs, and wiring harness are a factory-calibrated and assembled unit. Any time any one of these components is removed or replaced for any reason, the OCM must be re-calibrated using a diagnostic scan tool, the Occupant Classification Seat Weight special tool 9077, and the Occupant Classification System Verification Test. Refer to the appropriate diagnostic procedures. The OCM cannot be adjusted or repaired and, if damaged or faulty, it must be replaced. The OCM software is flash programmable. A non-calibrated OCM is available for separate service replacement. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Description and Operation > Description > Page 7875 Seat Occupant Classification Module - Air Bag: Description and Operation Operation OPERATION The microprocessor in the Occupant Classification Module (OCM) contains the Occupant Classification System (OCS) logic circuits. The OCM uses On-Board Diagnostics (OBD) and can communicate with other electronic modules in the vehicle as well as with the diagnostic scan tool using the Controller Area Network (CAN) data bus. This method of communication is also used for OCS diagnosis and testing through the 16-way Data Link Connector (DLC) located on the driver side lower edge of the instrument panel. The OCM provides voltage to the four seat weight sensors located on each of the four corners of the passenger side front seat, and to the seat track position sensors located on the passenger and driver front seat tracks. The OCM then monitors return inputs from each of the sensors on dedicated hard wired data communication circuits. The seat weight sensor input allows the OCM to determine whether the passenger front seat is occupied and the relative size of the occupant by providing a weight-sensing reference to the load on the seat. The seat track position sensor provides an additional logic input to the OCM microprocessor that allows it to determine the position of the front seat passenger and driver relative to the front airbags. Pre-programmed decision algorithms and OCS calibration allow the OCM microprocessor to determine when passenger airbag protection is appropriate based upon the seat load as signaled by the seat weight sensors. When the programmed conditions are met, the OCM sends the proper electronic occupant classification messages over the CAN data bus to the Occupant Restraint Controller (ORC), and the ORC enables or disables the deployment circuits for the passenger front supplemental restraints. On vehicles so equipped, the ORC also provides a control output for the passenger airbag on/off indicator in the instrument panel based upon the electronic occupant classification messages it receives from the OCM. The OCM also sends electronic driver and passenger seat track position messages to the ORC over the CAN data bus. The ORC uses the seat track position data as an additional logic input for determining the force level with which to deploy the multistage front airbags. The OCM microprocessor continuously monitors all of the OCS electrical circuits and components to determine the system readiness. If the OCM detects a monitored system fault, it sets an active and stored Diagnostic Trouble Code (DTC) and sends the appropriate electronic messages to the ORC over the CAN data bus. Then the ORC sets a DTC and sends messages to control the airbag indicator operation accordingly. An active fault only remains for the duration of the fault, or in some cases for the duration of the current ignition switch cycle, while a stored fault causes a DTC to be stored in memory by the OCM and the ORC. For some DTC's, if a fault does not recur for a number of ignition cycles, the OCM will automatically erase the stored DTC. For other internal faults, the stored DTC is latched forever. The OCM receives battery current on a fused ignition switch output (run-start) circuit through a fuse in the Junction Block (JB). The OCM receives ground through a ground circuit of the body wire harness. These connections allow the OCM to be operational whenever the ignition switch is in the Start or On positions. To diagnose the OCM and all its inputs, outputs and related circuits, use a diagnostic scan tool and the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Service and Repair > Removal Seat Occupant Classification Module - Air Bag: Service and Repair Removal REMOVAL WARNING: The replacement Occupant Classification Module (OCM) is a non-calibrated unit when first installed. The OCM and all of the other components of the Occupant Classification System (OCS) including the passenger front seat, the seat weight sensors, the passenger or driver seat track position sensor and the seat adjusters, cushion, back, frame, foam, springs, and wiring harness are a factory-calibrated and assembled unit. Any time any one of these components is removed or replaced for any reason, the OCM must be re-calibrated using a diagnostic scan tool, the Occupant Classification Seat Weight special tool 9077, and the Occupant Classification System Verification Test. Refer to the appropriate diagnostic procedures. 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. 2. Reach under the front edge of the passenger side front seat cushion to access and remove the two screws that secure the Occupant Classification Module (OCM) (3) to the underside of the passenger front seat cushion pan. 3. Pull the OCM down far enough to access the module wiring connections (4). 4. Disconnect the two electrical connectors (4) from the OCM (3). 5. Remove the OCM (3) from under the passenger front seat. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Service and Repair > Removal > Page 7878 Seat Occupant Classification Module - Air Bag: Service and Repair Installation INSTALLATION WARNING: A non-calibrated Occupant Classification Module (OCM) is available for separate service replacement. The OCM and all of the other components of the Occupant Classification System (OCS) including the passenger side front seat, the seat weight sensors, the passenger or driver seat track position sensor and the seat adjusters, cushion, back, frame, foam, springs, and wiring harness are a factory-calibrated and assembled unit. Any time any one of these components is removed or replaced for any reason, the OCM must be re-calibrated using a diagnostic scan tool, the Occupant Classification Seat Weight special tool 9077, and the Occupant Classification System Verification Test. Refer to the appropriate diagnostic procedures. 1. Position the Occupant Classification Module (OCM) (3) under the passenger front seat cushion. 2. Connect the two electrical connectors (4) to the OCM (3). 3. Carefully position the OCM to the seat cushion pan. 4. Install the two screws that secure the OCM to the seat cushion pan. WARNING: Do not connect the battery negative cable. Personal injury or death may result if the system test is not performed first. WARNING: Following successful completion of the Airbag System verification test procedure, perform the Occupant Classification System Verification Test using a diagnostic scan tool and the Occupant Classification Seat Weight special tool 9077. Refer to the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Description and Operation Child Seat Tether Attachment: Description and Operation DESCRIPTION The Lower Anchors and Tether for Children, or LATCH child restraint anchorage system provides for the installation of suitable child restraints in certain seating positions without using the seat belt provided for that seating position. The second row seats are equipped with a fixed-position child restraint upper tether anchor for all three seating positions. There are child restraint lower anchors for both outboard seating positions in the second row. The left lower anchors are permanently mounted on the second row seat hinge, along with the right outboard lower anchor. The right inboard lower anchor is mounted on a bracket mounted to the seat floor pan. These anchors are constructed from a heavy-gauge steel wire loop. They are each accessed from the front of their respective seats, at each side where the seat back meets the seat cushion. These lower anchors cannot be adjusted or repaired and, if faulty or damaged, the entire mounting assembly must be replaced, either the right inboard bracket or seat hinge(s). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Seat Belt Retractor Seat Belt: Service and Repair Front Seat Belt Retractor Removal REMOVAL WARNING: Due to the integral tensioners, the front seat belt retractor assemblies must be replaced following a collision where the airbags were deployed. 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the system reserve capacitor to discharge before servicing any airbag components. 2. Using a trim stick or equivalent, gently pry off the trim cover (1) to the retractor lower anchor bolt (2). 3. Remove the lower anchor bolt (2). 4. Using a trim stick or equivalent, gently pry off the plastic turning loop cover (2) from the height adjuster (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Seat Belt Retractor > Page 7888 5. Remove the bolt (4) attaching the turning loop to the belt height adjuster (2). 6. Remove upper B-pillar trim (3) and lower B-pillar trim panels. 7. Using a trim stick or equivalent, gently pry the seatbelt webbing guide from the B-pillar (1). 8. Remove anchor bolt (6) from lower B-pillar (1). 9. Disconnect electrical connectors. One is for the tensioner squib (2) and the other is for the seat belt switch (3). 10. Remove front seat belt retractor (1) from vehicle. Installation INSTALLATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Seat Belt Retractor > Page 7889 WARNING: Due to the integral tensioners, the front seat belt retractor assemblies must be replaced following a collision where the airbags were deployed. 1. Position the front seat belt retractor (1) into B-pillar pocket. 2. Connect electrical connectors. One is for the tensioner squib (2) and the other is for the seat belt switch (3). 3. Install the anchor bolt (6) to the lower B-pillar (1). Tighten bolt to 40 Nm (29.5 ft. lbs.). 4. Install the seatbelt webbing guide into the B-pillar (1). 5. Install the lower B-pillar trim and upper B-pillar trim (3). 6. Install the bolt (4) attaching the turning loop to the belt height adjuster (2). Tighten bolt to 40 Nm (29.5 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Seat Belt Retractor > Page 7890 7. Install the plastic turning loop cover (2) onto the height adjuster (1). 8. Install the lower webbing anchor bolt (2) to the seat cushion frame (4). Tighten bolt to 51 Nm (37.5 ft. lbs.). 9. Install the trim cover (1) to the retractor lower anchor bolt (2). WARNING: Do not connect the battery negative cable. Personal injury or death may result if the system test is not performed first. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Seat Belt Retractor > Page 7891 Seat Belt: Service and Repair Rear Center Seat Belt Retractor Removal REMOVAL 1. If center rear seatbelt (1) is latched to its anchor, detach the Quick Connect Anchor by depressing tab (2). 2. If seatbelt is unlatched from its anchor then remove it from its stowage slot on the right quarter trim panel. 3. Remove C-pillar upper trim panel (1). 4. Feed seatbelt webbing through C-pillar upper trim panel. 5. Remove the rear center seatbelt upper turning loop bolt (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Seat Belt Retractor > Page 7892 6. Remove the rear center seatbelt retractor retaining bolt (5) from the D-pillar (3). 7. Remove rear center seatbelt retractor (4) from the vehicle. Installation INSTALLATION 1. Position rear center seatbelt retractor into hollow in the D-pillar (3). 2. Install the rear center seatbelt retractor retaining bolt (5). Tighten bolt to 40 Nm (29.5 ft. lbs.). 3. Feed seatbelt webbing through upper C-pillar trim panel. 4. Install the upper C-pillar trim panel. 5. If replacing the seatbelt into the latch stowage, place into slot and push down. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Seat Belt Retractor > Page 7893 6. If latching seatbelt (1) to anchor (2), attach Quick Connect Anchor (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Seat Belt Retractor > Page 7894 Seat Belt: Service and Repair Rear Seat Belt Retractor Removal REMOVAL 1. Remove the upper C-pillar trim (6). 2. Remove the rear quarter panel trim. 3. Remove the rear outer seatbelt anchor bolt (2). 4. Feed the seatbelt webbing through the upper C-pillar trim panel (6). 5. Remove the upper seatbelt turning loop bolt (5). 6. Remove the rear outer seatbelt retractor retaining bolt (3). 7. Remove the rear outer seatbelt retractor (4) from the C-pillar (1). Installation INSTALLATION 1. Position the rear outer seatbelt retractor (4) into the C-pillar (1). 2. Install the rear outer seatbelt retractor retaining bolt (3). Tighten bolt to 40 Nm (29.5 ft. lbs.). 3. Install the upper seatbelt turning loop bolt (5). Tighten bolt to 40 Nm (29.5 ft. lbs.). 4. Feed the seatbelt webbing through the upper C-pillar trim panel (6). 5. Install the rear outer seatbelt anchor bolt (2). Tighten bolt to 40 Nm (29.5 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Seat Belt Retractor > Page 7895 6. Install the rear quarter panel trim. 7. Install upper C-pillar trim (6). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Buckle-Front Seat Belt Seat Belt Buckle: Service and Repair Buckle-Front Seat Belt Removal REMOVAL 1. Remove the inboard cushion trim cover. 2. Remove the seat belt buckle bolt (3). 3. Remove the buckle (1) from the adjuster (3). Installation INSTALLATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Buckle-Front Seat Belt > Page 7900 1. Install the seat belt buckle (1) onto the seat adjuster (2). 2. Install the anchor bolt (3) and tighten bolt to 51 Nm (37.5 ft. lbs.). 3. Install the cushion side cover. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Buckle-Front Seat Belt > Page 7901 Seat Belt Buckle: Service and Repair Buckle-Rear Seat Belt Center/Left Buckle CENTER/LEFT BUCKLE 1. Remove the rear seat cushion. 2. Remove the left and center seatbelt buckle retaining bolt (2). 3. Remove the left and center seatbelt buckle (1) from the vehicle. Right Buckle/Center Seat Belt Anchor Latch RIGHT BUCKLE/CENTER SEAT BELT ANCHOR LATCH 1. Remove the rear seat cushion. 2. Remove the right buckle/center seatbelt anchor latch retaining bolt (2). 3. Remove the right buckle/center seatbelt anchor latch (1) from the vehicle. Center/Left Buckle CENTER/LEFT BUCKLE Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Buckle-Front Seat Belt > Page 7902 1. Position the buckle (1) over the left inner seat back hinge and install the retaining bolt (2). Tighten bolt to 56 Nm (41.5 ft. lbs.). 2. Install the rear seat cushion. Right Buckle/Center Seat Belt Anchor Latch RIGHT BUCKLE/CENTER SEAT BELT ANCHOR LATCH 1. Position the right buckle/center seatbelt anchor latch (1) in the vehicle. 2. Install the right buckle/center seatbelt anchor latch retaining bolt (2). Tighten bolt to 56 Nm (41.5 ft. lbs.). 3. Install the rear seat cushion. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Removal Seat Belt Height Adjuster: Service and Repair Removal REMOVAL 1. Firmly grasp the turning loop cover (2) and pull inward to remove from height adjuster. 2. Remove the one bolt to the front seat belt retractor turning loop (4). 3. Remove Upper B-pillar trim. 4. Remove the two bolts (2) attaching front seat belt height adjuster (3) to B-pillar (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Removal > Page 7907 5. Remove front seat belt height adjuster (3) from vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Removal > Page 7908 Seat Belt Height Adjuster: Service and Repair Installation INSTALLATION 1. Install front seat belt height adjuster (3) in vehicle. 2. Tighten the two bolts (2) attaching front seat belt height adjuster (3) to B-pillar (1) to 40 Nm (29.5 ft. lbs.). 3. Install the upper B-pillar trim. 4. Install the one bolt to the front seat belt retractor turning loop (4). Tighten bolt to 40 Nm (29.5 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Removal > Page 7909 5. Snap the turning loop cover (2) onto the height adjuster. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Description and Operation Seat Belt Reminder Lamp: Description and Operation FASTEN SEAT BELTS To test the fasten seat belts function, turn the ignition switch to the ON position with the driver's seat belt unbuckled and fully retracted. The seat belt warning lamp should light for four to eight seconds and the tone should sound three to five times. If the lamp does not light, check the connection at the seat belt retractor. Replace as necessary. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Seat Belt Retractor Seat Belt Retractor: Service and Repair Front Seat Belt Retractor Removal REMOVAL WARNING: Due to the integral tensioners, the front seat belt retractor assemblies must be replaced following a collision where the airbags were deployed. 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the system reserve capacitor to discharge before servicing any airbag components. 2. Using a trim stick or equivalent, gently pry off the trim cover (1) to the retractor lower anchor bolt (2). 3. Remove the lower anchor bolt (2). 4. Using a trim stick or equivalent, gently pry off the plastic turning loop cover (2) from the height adjuster (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Seat Belt Retractor > Page 7917 5. Remove the bolt (4) attaching the turning loop to the belt height adjuster (2). 6. Remove upper B-pillar trim (3) and lower B-pillar trim panels. 7. Using a trim stick or equivalent, gently pry the seatbelt webbing guide from the B-pillar (1). 8. Remove anchor bolt (6) from lower B-pillar (1). 9. Disconnect electrical connectors. One is for the tensioner squib (2) and the other is for the seat belt switch (3). 10. Remove front seat belt retractor (1) from vehicle. Installation INSTALLATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Seat Belt Retractor > Page 7918 WARNING: Due to the integral tensioners, the front seat belt retractor assemblies must be replaced following a collision where the airbags were deployed. 1. Position the front seat belt retractor (1) into B-pillar pocket. 2. Connect electrical connectors. One is for the tensioner squib (2) and the other is for the seat belt switch (3). 3. Install the anchor bolt (6) to the lower B-pillar (1). Tighten bolt to 40 Nm (29.5 ft. lbs.). 4. Install the seatbelt webbing guide into the B-pillar (1). 5. Install the lower B-pillar trim and upper B-pillar trim (3). 6. Install the bolt (4) attaching the turning loop to the belt height adjuster (2). Tighten bolt to 40 Nm (29.5 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Seat Belt Retractor > Page 7919 7. Install the plastic turning loop cover (2) onto the height adjuster (1). 8. Install the lower webbing anchor bolt (2) to the seat cushion frame (4). Tighten bolt to 51 Nm (37.5 ft. lbs.). 9. Install the trim cover (1) to the retractor lower anchor bolt (2). WARNING: Do not connect the battery negative cable. Personal injury or death may result if the system test is not performed first. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Seat Belt Retractor > Page 7920 Seat Belt Retractor: Service and Repair Rear Center Seat Belt Retractor Removal REMOVAL 1. If center rear seatbelt (1) is latched to its anchor, detach the Quick Connect Anchor by depressing tab (2). 2. If seatbelt is unlatched from its anchor then remove it from its stowage slot on the right quarter trim panel. 3. Remove C-pillar upper trim panel (1). 4. Feed seatbelt webbing through C-pillar upper trim panel. 5. Remove the rear center seatbelt upper turning loop bolt (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Seat Belt Retractor > Page 7921 6. Remove the rear center seatbelt retractor retaining bolt (5) from the D-pillar (3). 7. Remove rear center seatbelt retractor (4) from the vehicle. Installation INSTALLATION 1. Position rear center seatbelt retractor into hollow in the D-pillar (3). 2. Install the rear center seatbelt retractor retaining bolt (5). Tighten bolt to 40 Nm (29.5 ft. lbs.). 3. Feed seatbelt webbing through upper C-pillar trim panel. 4. Install the upper C-pillar trim panel. 5. If replacing the seatbelt into the latch stowage, place into slot and push down. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Seat Belt Retractor > Page 7922 6. If latching seatbelt (1) to anchor (2), attach Quick Connect Anchor (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Seat Belt Retractor > Page 7923 Seat Belt Retractor: Service and Repair Rear Seat Belt Retractor Removal REMOVAL 1. Remove the upper C-pillar trim (6). 2. Remove the rear quarter panel trim. 3. Remove the rear outer seatbelt anchor bolt (2). 4. Feed the seatbelt webbing through the upper C-pillar trim panel (6). 5. Remove the upper seatbelt turning loop bolt (5). 6. Remove the rear outer seatbelt retractor retaining bolt (3). 7. Remove the rear outer seatbelt retractor (4) from the C-pillar (1). Installation INSTALLATION 1. Position the rear outer seatbelt retractor (4) into the C-pillar (1). 2. Install the rear outer seatbelt retractor retaining bolt (3). Tighten bolt to 40 Nm (29.5 ft. lbs.). 3. Install the upper seatbelt turning loop bolt (5). Tighten bolt to 40 Nm (29.5 ft. lbs.). 4. Feed the seatbelt webbing through the upper C-pillar trim panel (6). 5. Install the rear outer seatbelt anchor bolt (2). Tighten bolt to 40 Nm (29.5 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Seat Belt Retractor > Page 7924 6. Install the rear quarter panel trim. 7. Install upper C-pillar trim (6). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Locations > Seat Belt-Tensioner-Driver Seat Belt Tensioner: Locations Seat Belt-Tensioner-Driver Component ID: 279 Component : SEAT BELT-TENSIONER-DRIVER Connector: Name : SEAT BELT-TENSIONER-DRIVER Color : YELLOW/BLACK # of pins : 2 Pin Description Circuit 1 DRIVER SEAT BELT TENSIONER LINE 2 R53 18LG/YL 2 DRIVER SEAT BELT TENSIONER LINE 1 R55 18LG/DG Component Location - 48 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Locations > Seat Belt-Tensioner-Driver > Page 7929 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Locations > Seat Belt-Tensioner-Driver > Page 7930 Seat Belt Tensioner: Locations Seat Belt-Tensioner-Passenger Component ID: 280 Component : SEAT BELT-TENSIONER-PASSENGER Connector: Name : SEAT BELT-TENSIONER-PASSENGER Color : YELLOW/BLACK # of pins : 2 Pin Description Circuit 1 PASSENGER SEAT BELT TENSIONER LINE 2R54 18LB/YL 2 PASSENGER SEAT BELT TENSIONER LINE 1R56 18LB/DG Component Location - 50 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Locations > Seat Belt-Tensioner-Driver > Page 7931 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Seat Belt-Tensioner-Driver Seat Belt Tensioner: Diagrams Seat Belt-Tensioner-Driver Component ID: 279 Component : SEAT BELT-TENSIONER-DRIVER Connector: Name : SEAT BELT-TENSIONER-DRIVER Color : YELLOW/BLACK # of pins : 2 Pin Description Circuit 1 DRIVER SEAT BELT TENSIONER LINE 2 R53 18LG/YL 2 DRIVER SEAT BELT TENSIONER LINE 1 R55 18LG/DG Component Location - 48 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Seat Belt-Tensioner-Driver > Page 7934 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Seat Belt-Tensioner-Driver > Page 7935 Seat Belt Tensioner: Diagrams Seat Belt-Tensioner-Passenger Component ID: 280 Component : SEAT BELT-TENSIONER-PASSENGER Connector: Name : SEAT BELT-TENSIONER-PASSENGER Color : YELLOW/BLACK # of pins : 2 Pin Description Circuit 1 PASSENGER SEAT BELT TENSIONER LINE 2R54 18LB/YL 2 PASSENGER SEAT BELT TENSIONER LINE 1R56 18LB/DG Component Location - 50 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Seat Belt-Tensioner-Driver > Page 7936 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Description and Operation > Description Seat Belt Tensioner: Description and Operation Description DESCRIPTION Seat belt tensioners supplement the dual front airbags for this vehicle. The seat belt tensioners are integral to the front outboard seat belt retractor units, which are secured to the inner B-pillar on the right and left sides of the vehicle. The retractor is concealed beneath the molded plastic inner B-pillar trim. The seat belt tensioner consists primarily of a sprocket/pinion, a steel tube, a cast metal housing, numerous steel balls, a stamped metal ball trap, a torsion bar and a small pyrotechnically activated gas generator with a connector receptacle. All of these components are located on one side of the retractor spool on the outside of the retractor housing except for the torsion bar, which serves as the spindle upon which the retractor spool rides. The seat belt tensioners are controlled by the Occupant Restraint Controller (ORC) and are connected to the vehicle electrical system through a dedicated take out of the body wire harness by a keyed and latching yellow molded plastic connector insulator to ensure a secure connection. The seat belt tensioners cannot be repaired and, if ineffective or damaged, the entire front seat belt and retractor unit must be replaced. If the front airbags have been deployed, the seat belt tensioners have also been deployed. The seat belt tensioners are not intended for reuse and must be replaced following any front airbag deployment. A growling or grinding sound while attempting to operate the seat belt retractor is a sure indication that the seat belt tensioner has been deployed and requires replacement. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Description and Operation > Description > Page 7939 Seat Belt Tensioner: Description and Operation Operation OPERATION The seat belt tensioners are deployed in conjunction with the dual front airbags by a signal generated by the Occupant Restraint Controller (ORC) through the driver or passenger seat belt tensioner line 1 and line 2 (or squib) circuits. When the ORC sends the proper electrical signal to the tensioners, the electrical energy generates enough heat to initiate a small pyrotechnic gas generator. The gas generator is installed in one end of a steel tube that contains numerous steel balls. As the gas expands, it pushes the steel balls through the tube into a cast metal housing, where a ball guide directs the balls into engagement with the teeth of a sprocket that is geared to one end of the retractor spool. As the balls drive past the sprocket, the sprocket turns and drives the seat belt retractor spool causing the slack to be removed from the front seat belts. The ball trap captures the balls as they leave the sprocket and are expelled from the housing. Removing excess slack from the front seat belts not only keeps the occupants properly positioned for an airbag deployment following a frontal impact of the vehicle, but also helps to reduce injuries that the occupant might experience in these situations as a result of harmful contact with the steering wheel, steering column, instrument panel or windshield. Also, the seat belt tensioner torsion bar that the retractor spool rides upon is designed to deform in order to control the loading being applied to the occupants by the seat belts during a frontal impact, further reducing the potential for occupant injuries. The ORC monitors the condition of the seat belt tensioners through circuit resistance, and will illuminate the airbag indicator in the Electromechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) and store a Diagnostic Trouble Code (DTC) for any fault that is detected. Proper diagnosis of the seat belt tensioner gas generator and the seat belt tensioner squib circuits requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver Seat Sensor/Switch: Locations Sensor-Seat Track Position-Driver Component ID: 306 Component : SENSOR-SEAT TRACK POSITION-DRIVER Connector: Name : SENSOR-SEAT TRACK POSITION-DRIVER Color : DK. GRAY # of pins : 2 Pin Description Circuit 1 DRIVER SEAT POSITION SENSOR DATA R261 20LB/WT 2 DRIVER SEAT POSITION SENSOR VOLTAGER263 20LB/VT Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 7944 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 7945 Seat Sensor/Switch: Locations Sensor-Seat Track Position-Passenger Component ID: 307 Component : SENSOR-SEAT TRACK POSITION-PASSENGER Connector: Name : SENSOR-SEAT TRACK POSITION-PASSENGER Color : DK. GRAY # of pins : 2 Pin Description Circuit 1 PASSENGER SEAT POSITION SENSOR DATAR262 20WT/LB 2 PASSENGER SEAT POSITION SENSOR VOLTAGE R264 20VT/LB Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 7946 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 7947 Seat Sensor/Switch: Locations Sensor-Seat Weight-Left Front Component ID: 308 Component : SENSOR-SEAT WEIGHT-LEFT FRONT Connector: Name : SENSOR-SEAT WEIGHT-LEFT FRONT Color : BLACK # of pins : 3 Pin Description Circuit 1 SEAT WEIGHT SENSOR GROUND R728 20LB/YL 2 SEAT WEIGHT LEFT FRONT SENSOR SIGNAL R717 20LG/DG 3 SEAT WEIGHT SENSOR 5 VOLT R701 20LG Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 7948 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 7949 Seat Sensor/Switch: Locations Sensor-Seat Weight-Left Rear Component ID: 309 Component : SENSOR-SEAT WEIGHT-LEFT REAR Connector: Name : SENSOR-SEAT WEIGHT-LEFT REAR Color : BLACK # of pins : 3 Pin Description Circuit 1 SEAT WEIGHT SENSOR GROUND R728 20LB/YL 2 SEAT WEIGHT LEFT REAR SENSOR SIGNALR705 20LG/OR 3 SEAT WEIGHT SENSOR 5 VOLT R701 20LG Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 7950 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 7951 Seat Sensor/Switch: Locations Sensor-Seat Track Position-Driver Component ID: 306 Component : SENSOR-SEAT TRACK POSITION-DRIVER Connector: Name : SENSOR-SEAT TRACK POSITION-DRIVER Color : DK. GRAY # of pins : 2 Pin Description Circuit 1 DRIVER SEAT POSITION SENSOR DATA R261 20LB/WT 2 DRIVER SEAT POSITION SENSOR VOLTAGER263 20LB/VT Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 7952 Sensor-Seat Track Position-Passenger Component ID: 307 Component : SENSOR-SEAT TRACK POSITION-PASSENGER Connector: Name : SENSOR-SEAT TRACK POSITION-PASSENGER Color : DK. GRAY # of pins : 2 Pin Description Circuit Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 7953 1 PASSENGER SEAT POSITION SENSOR DATAR262 20WT/LB 2 PASSENGER SEAT POSITION SENSOR VOLTAGE R264 20VT/LB Component Location - 57 Sensor-Seat Weight-Left Front Component ID: 308 Component : SENSOR-SEAT WEIGHT-LEFT FRONT Connector: Name : SENSOR-SEAT WEIGHT-LEFT FRONT Color : BLACK # of pins : 3 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 7954 Pin Description Circuit 1 SEAT WEIGHT SENSOR GROUND R728 20LB/YL 2 SEAT WEIGHT LEFT FRONT SENSOR SIGNAL R717 20LG/DG 3 SEAT WEIGHT SENSOR 5 VOLT R701 20LG Component Location - 57 Sensor-Seat Weight-Left Rear Component ID: 309 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 7955 Component : SENSOR-SEAT WEIGHT-LEFT REAR Connector: Name : SENSOR-SEAT WEIGHT-LEFT REAR Color : BLACK # of pins : 3 Pin Description Circuit 1 SEAT WEIGHT SENSOR GROUND R728 20LB/YL 2 SEAT WEIGHT LEFT REAR SENSOR SIGNALR705 20LG/OR 3 SEAT WEIGHT SENSOR 5 VOLT R701 20LG Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 7956 Sensor-Seat Weight-Right Front Component ID: 310 Component : SENSOR-SEAT WEIGHT-RIGHT FRONT Connector: Name : SENSOR-SEAT WEIGHT-RIGHT FRONT Color : BLACK # of pins : 3 Pin Description Circuit Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 7957 1 SEAT WEIGHT SENSOR GROUND R728 20LB/YL 2 SEAT WEIGHT RIGHT FRONT SENSOR SIGNAL R718 20LB/DG 3 SEAT WEIGHT SENSOR 5 VOLT R701 20LG Component Location - 57 Sensor-Seat Weight-Right Rear Component ID: 311 Component : SENSOR-SEAT WEIGHT-RIGHT REAR Connector: Name : SENSOR-SEAT WEIGHT-RIGHT REAR Color : BLACK # of pins : 3 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 7958 Pin Description Circuit 1 SEAT WEIGHT SENSOR GROUND R728 20LB/YL 2 SEAT WEIGHT RIGHT REAR SENSOR SIGNAL R706 20LB/OR 3 SEAT WEIGHT SENSOR 5 VOLT R701 20LG Component Location - 57 Switch-Seat Belt-Driver Component ID: 355 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 7959 Component : SWITCH-SEAT BELT-DRIVER Connector: Name : SWITCH-SEAT BELT-DRIVER Color : BLACK # of pins : 2 Pin Description Circuit 1 DRIVER SEAT BELT SWITCH SENSE R57 20LG/GY 2 GROUND Z961 20BK/YL Component Location - 48 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 7960 Switch-Seat Belt-Passenger Component ID: 356 Component : SWITCH-SEAT BELT-PASSENGER Connector: Name : SWITCH-SEAT BELT-PASSENGER Color : WHITE # of pins : 2 Pin Description Circuit Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 7961 1 PASSENGER HALL EFFECT (+) R274 20LB/WT 2 PASSENGER HALL EFFECT (-) R272 20LB/VT Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver Seat Sensor/Switch: Diagrams Sensor-Seat Track Position-Driver Component ID: 306 Component : SENSOR-SEAT TRACK POSITION-DRIVER Connector: Name : SENSOR-SEAT TRACK POSITION-DRIVER Color : DK. GRAY # of pins : 2 Pin Description Circuit 1 DRIVER SEAT POSITION SENSOR DATA R261 20LB/WT 2 DRIVER SEAT POSITION SENSOR VOLTAGER263 20LB/VT Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 7964 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 7965 Seat Sensor/Switch: Diagrams Sensor-Seat Track Position-Passenger Component ID: 307 Component : SENSOR-SEAT TRACK POSITION-PASSENGER Connector: Name : SENSOR-SEAT TRACK POSITION-PASSENGER Color : DK. GRAY # of pins : 2 Pin Description Circuit 1 PASSENGER SEAT POSITION SENSOR DATAR262 20WT/LB 2 PASSENGER SEAT POSITION SENSOR VOLTAGE R264 20VT/LB Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 7966 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 7967 Seat Sensor/Switch: Diagrams Sensor-Seat Weight-Left Front Component ID: 308 Component : SENSOR-SEAT WEIGHT-LEFT FRONT Connector: Name : SENSOR-SEAT WEIGHT-LEFT FRONT Color : BLACK # of pins : 3 Pin Description Circuit 1 SEAT WEIGHT SENSOR GROUND R728 20LB/YL 2 SEAT WEIGHT LEFT FRONT SENSOR SIGNAL R717 20LG/DG 3 SEAT WEIGHT SENSOR 5 VOLT R701 20LG Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 7968 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 7969 Seat Sensor/Switch: Diagrams Sensor-Seat Weight-Left Rear Component ID: 309 Component : SENSOR-SEAT WEIGHT-LEFT REAR Connector: Name : SENSOR-SEAT WEIGHT-LEFT REAR Color : BLACK # of pins : 3 Pin Description Circuit 1 SEAT WEIGHT SENSOR GROUND R728 20LB/YL 2 SEAT WEIGHT LEFT REAR SENSOR SIGNALR705 20LG/OR 3 SEAT WEIGHT SENSOR 5 VOLT R701 20LG Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 7970 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 7971 Seat Sensor/Switch: Diagrams Sensor-Seat Track Position-Driver Component ID: 306 Component : SENSOR-SEAT TRACK POSITION-DRIVER Connector: Name : SENSOR-SEAT TRACK POSITION-DRIVER Color : DK. GRAY # of pins : 2 Pin Description Circuit 1 DRIVER SEAT POSITION SENSOR DATA R261 20LB/WT 2 DRIVER SEAT POSITION SENSOR VOLTAGER263 20LB/VT Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 7972 Sensor-Seat Track Position-Passenger Component ID: 307 Component : SENSOR-SEAT TRACK POSITION-PASSENGER Connector: Name : SENSOR-SEAT TRACK POSITION-PASSENGER Color : DK. GRAY # of pins : 2 Pin Description Circuit Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 7973 1 PASSENGER SEAT POSITION SENSOR DATAR262 20WT/LB 2 PASSENGER SEAT POSITION SENSOR VOLTAGE R264 20VT/LB Component Location - 57 Sensor-Seat Weight-Left Front Component ID: 308 Component : SENSOR-SEAT WEIGHT-LEFT FRONT Connector: Name : SENSOR-SEAT WEIGHT-LEFT FRONT Color : BLACK # of pins : 3 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 7974 Pin Description Circuit 1 SEAT WEIGHT SENSOR GROUND R728 20LB/YL 2 SEAT WEIGHT LEFT FRONT SENSOR SIGNAL R717 20LG/DG 3 SEAT WEIGHT SENSOR 5 VOLT R701 20LG Component Location - 57 Sensor-Seat Weight-Left Rear Component ID: 309 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 7975 Component : SENSOR-SEAT WEIGHT-LEFT REAR Connector: Name : SENSOR-SEAT WEIGHT-LEFT REAR Color : BLACK # of pins : 3 Pin Description Circuit 1 SEAT WEIGHT SENSOR GROUND R728 20LB/YL 2 SEAT WEIGHT LEFT REAR SENSOR SIGNALR705 20LG/OR 3 SEAT WEIGHT SENSOR 5 VOLT R701 20LG Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 7976 Sensor-Seat Weight-Right Front Component ID: 310 Component : SENSOR-SEAT WEIGHT-RIGHT FRONT Connector: Name : SENSOR-SEAT WEIGHT-RIGHT FRONT Color : BLACK # of pins : 3 Pin Description Circuit Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 7977 1 SEAT WEIGHT SENSOR GROUND R728 20LB/YL 2 SEAT WEIGHT RIGHT FRONT SENSOR SIGNAL R718 20LB/DG 3 SEAT WEIGHT SENSOR 5 VOLT R701 20LG Component Location - 57 Sensor-Seat Weight-Right Rear Component ID: 311 Component : SENSOR-SEAT WEIGHT-RIGHT REAR Connector: Name : SENSOR-SEAT WEIGHT-RIGHT REAR Color : BLACK # of pins : 3 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 7978 Pin Description Circuit 1 SEAT WEIGHT SENSOR GROUND R728 20LB/YL 2 SEAT WEIGHT RIGHT REAR SENSOR SIGNAL R706 20LB/OR 3 SEAT WEIGHT SENSOR 5 VOLT R701 20LG Component Location - 57 Switch-Seat Belt-Driver Component ID: 355 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 7979 Component : SWITCH-SEAT BELT-DRIVER Connector: Name : SWITCH-SEAT BELT-DRIVER Color : BLACK # of pins : 2 Pin Description Circuit 1 DRIVER SEAT BELT SWITCH SENSE R57 20LG/GY 2 GROUND Z961 20BK/YL Component Location - 48 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 7980 Switch-Seat Belt-Passenger Component ID: 356 Component : SWITCH-SEAT BELT-PASSENGER Connector: Name : SWITCH-SEAT BELT-PASSENGER Color : WHITE # of pins : 2 Pin Description Circuit Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 7981 1 PASSENGER HALL EFFECT (+) R274 20LB/WT 2 PASSENGER HALL EFFECT (-) R272 20LB/VT Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left Impact Sensor: Locations Sensor-Front Impact-Left Component ID: 293 Component : SENSOR-FRONT IMPACT-LEFT Connector: Name : SENSOR-FRONT IMPACT-LEFT Color : YELLOW # of pins : 2 Pin Description Circuit 1 LEFT FRONT IMPACT SENSOR GROUND R81 20LB/WT 2 LEFT FRONT IMPACT SENSOR SIGNAL R79 20LB/VT Component Location - 7 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 7987 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 7988 Impact Sensor: Locations Sensor-Side Impact-Left 1 Component ID: 312 Component : SENSOR-SIDE IMPACT-LEFT 1 Connector: Name : SENSOR-SIDE IMPACT-LEFT 1 Color : YELLOW # of pins : 4 Pin Description Circuit 1 LEFT SIDE IMPACT SENSOR 1 SIGNAL R13 20LG/TN 2 LEFT SIDE IMPACT SENSOR 1 GROUND R15 20LG/BR 3 LEFT SIDE IMPACT SENSOR 2 GROUND R19 20LG/WT 4 LEFT SIDE IMPACT SENSOR 2 SIGNAL R17 20LG/LB Component Location - 48 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 7989 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 7990 Impact Sensor: Locations Sensor-Side Impact-Left 2 Component ID: 313 Component : SENSOR-SIDE IMPACT-LEFT 2 Connector: Name : SENSOR-SIDE IMPACT-LEFT 2 Color : YELLOW # of pins : 2 Pin Description Circuit 1 LEFT SIDE IMPACT SENSOR 2 GROUND R19 20LG/WT 2 LEFT SIDE IMPACT SENSOR 2 SIGNAL R17 20LG/LB Component Location - 60 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 7991 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 7992 Impact Sensor: Locations Sensor-Side Impact-Right 1 Component ID: 314 Component : SENSOR-SIDE IMPACT-RIGHT 1 Connector: Name : SENSOR-SIDE IMPACT-RIGHT 1 Color : YELLOW # of pins : 4 Pin Description Circuit 1 RIGHT SIDE IMPACT SENSOR 1 SIGNAL R14 20TN/LG 2 RIGHT SIDE IMPACT SENSOR 1 GROUND R16 20BR/LG 3 RIGHT SIDE IMPACT SENSOR 2 GROUND R20 20WT/LG 4 RIGHT SIDE IMPACT SENSOR 2 SIGNAL R18 20LB/LG Component Location - 50 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 7993 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 7994 Impact Sensor: Locations Sensor-Side Impact-Right 2 Component ID: 315 Component : SENSOR-SIDE IMPACT-RIGHT 2 Connector: Name : SENSOR-SIDE IMPACT-RIGHT 2 Color : YELLOW # of pins : 2 Pin Description Circuit 1 RIGHT SIDE IMPACT SENSOR 2 GROUND R20 20WT/LG 2 RIGHT SIDE IMPACT SENSOR 2 SIGNAL R18 20LB/LG Component Location - 63 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 7995 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left Impact Sensor: Diagrams Sensor-Front Impact-Left Component ID: 293 Component : SENSOR-FRONT IMPACT-LEFT Connector: Name : SENSOR-FRONT IMPACT-LEFT Color : YELLOW # of pins : 2 Pin Description Circuit 1 LEFT FRONT IMPACT SENSOR GROUND R81 20LB/WT 2 LEFT FRONT IMPACT SENSOR SIGNAL R79 20LB/VT Component Location - 7 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 7998 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 7999 Impact Sensor: Diagrams Sensor-Side Impact-Left 1 Component ID: 312 Component : SENSOR-SIDE IMPACT-LEFT 1 Connector: Name : SENSOR-SIDE IMPACT-LEFT 1 Color : YELLOW # of pins : 4 Pin Description Circuit 1 LEFT SIDE IMPACT SENSOR 1 SIGNAL R13 20LG/TN 2 LEFT SIDE IMPACT SENSOR 1 GROUND R15 20LG/BR 3 LEFT SIDE IMPACT SENSOR 2 GROUND R19 20LG/WT 4 LEFT SIDE IMPACT SENSOR 2 SIGNAL R17 20LG/LB Component Location - 48 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 8000 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 8001 Impact Sensor: Diagrams Sensor-Side Impact-Left 2 Component ID: 313 Component : SENSOR-SIDE IMPACT-LEFT 2 Connector: Name : SENSOR-SIDE IMPACT-LEFT 2 Color : YELLOW # of pins : 2 Pin Description Circuit 1 LEFT SIDE IMPACT SENSOR 2 GROUND R19 20LG/WT 2 LEFT SIDE IMPACT SENSOR 2 SIGNAL R17 20LG/LB Component Location - 60 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 8002 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 8003 Impact Sensor: Diagrams Sensor-Side Impact-Right 1 Component ID: 314 Component : SENSOR-SIDE IMPACT-RIGHT 1 Connector: Name : SENSOR-SIDE IMPACT-RIGHT 1 Color : YELLOW # of pins : 4 Pin Description Circuit 1 RIGHT SIDE IMPACT SENSOR 1 SIGNAL R14 20TN/LG 2 RIGHT SIDE IMPACT SENSOR 1 GROUND R16 20BR/LG 3 RIGHT SIDE IMPACT SENSOR 2 GROUND R20 20WT/LG 4 RIGHT SIDE IMPACT SENSOR 2 SIGNAL R18 20LB/LG Component Location - 50 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 8004 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 8005 Impact Sensor: Diagrams Sensor-Side Impact-Right 2 Component ID: 315 Component : SENSOR-SIDE IMPACT-RIGHT 2 Connector: Name : SENSOR-SIDE IMPACT-RIGHT 2 Color : YELLOW # of pins : 2 Pin Description Circuit 1 RIGHT SIDE IMPACT SENSOR 2 GROUND R20 20WT/LG 2 RIGHT SIDE IMPACT SENSOR 2 SIGNAL R18 20LB/LG Component Location - 63 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 8006 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Front Impact Sensor: Description and Operation Front Description FRONT Two front impact sensors (1) are used on this vehicle, one each for the left and right sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). Each front sensor is secured with a screw to the backs of the right and left vertical members of the radiator support within the engine compartment. The right and left front impact sensors are identical in construction and calibration. A cavity in the center of the molded black plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material that fills the cavity to seal and protect the internal electronic circuitry and components. The front impact sensors are each connected to the vehicle electrical system through the headlamp and dash wire harness. The impact sensors cannot be repaired or adjusted and, if damaged or ineffective, they must be replaced. Operation FRONT The front impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the passive restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through dedicated left and right sensor plus and minus circuits from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor plus circuit. To diagnose the impact sensors or the electronic controls and communication related to front impact sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Front > Page 8009 Impact Sensor: Description and Operation Side Description SIDE Four side impact sensors (1) are used on this vehicle when it is equipped with the optional side airbags, two each for the left and right sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). Each side sensor is secured with a screw to the right or left B-pillar and C-pillar. The right and left side impact sensors are identical in construction and calibration. A cavity in the center of the molded black plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material fills the cavity to seal and protect the internal electronic circuitry and components. The side impact sensors are each connected to the vehicle electrical system through the body wire harness. The impact sensors cannot be repaired or adjusted and, if damaged or ineffective, they must be replaced. Operation SIDE The side impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the side passive restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through the same left or right sensor plus and minus circuits in a series arrangement from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor plus circuit. To diagnose the impact sensors or the electronic controls and communication related to side impact sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal Impact Sensor: Service and Repair Removal Front FRONT 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the system reserve capacitor to discharge before servicing any airbag components. 2. Remove the screw (4) that secures the right or left front impact sensor (3) to the back of the right or left radiator support vertical member (2). 3. Disconnect the connector (1) from the sensor (3). 4. Remove the right or left front impact sensor from the engine compartment. Side - B-Pillar SIDE - B-PILLAR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal > Page 8012 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the system reserve capacitor to discharge before servicing any airbag components. 2. Remove the B-pillar lower trim panel. 3. Disconnect the harness connector (4) from the sensor (2). 4. Remove the screw (1) retaining the B-pillar side impact sensor (2) 5. Remove the sensor (2) from the vehicle. Side - C-Pillar SIDE - C-PILLAR 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the system reserve capacitor to discharge before servicing any airbag components. 2. Remove the rear quarter panel trim. 3. Remove the screw (4) that secures the side impact sensor (3) to the C-pillar (1). 4. Disconnect the harness connector (2) from the sensor (3). 5. Remove the sensor from the C-pillar. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal > Page 8013 Impact Sensor: Service and Repair Installation Front FRONT 1. Position the right or left front impact sensor (3) into the engine compartment near it mounting area. 2. Connect the harness connector (1) to the sensor. 3. Position the sensor onto the back of the right or left radiator support vertical member (2). NOTE: Be certain that the anti-rotation pin on the back of the sensor is engaged in the lower clearance hole of the radiator support. 4. Install and tighten the screw (4) that secures the sensor (3) to the back of the support vertical member (2). Tighten the screw to 8 Nm (71 in. lbs.). WARNING: Do not connect the battery negative cable. Personal injury or death may result if the system test is not performed first. Side - B-Pillar SIDE - B-PILLAR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal > Page 8014 1. Position the sensor onto the B-pillar and install the mounting screw (1). Tighten the screw to 8 Nm (71 in. lbs.). NOTE: Be certain that the anti-rotation pin on the back of the sensor is engaged in the hole just below the mounting hole in the B-pillar (3). 2. Connect the harness connector (4) to the sensor (2). 3. Install the B-pillar lower trim panel. WARNING: Do not connect the battery negative cable. Personal injury or death may result if the system test is not performed first. Side - C-Pillar SIDE - C-PILLAR 1. Position the side impact sensor near the inner C-pillar. 2. Connect the harness connector (2) to the sensor (3). 3. Position the sensor onto the C-pillar. NOTE: Be certain that the anti-rotation pin on the back of the sensor is engaged in the clearance hole on the C-pillar below the sensor mounting hole. 4. Install screw (4) that secures the sensor (3) to the C-pillar (1). Tighten the screw to 8 Nm (71 in. lbs.). 5. Install the rear quarter panel trim. WARNING: Do not connect the battery negative cable. Personal injury or death may result if the system test is not performed first. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Description and Operation > Description Seat Occupant Sensor: Description and Operation Description DESCRIPTION The seat weight sensors are strain gauge-type units. The electronic elements of the sensor are encased within the sensor body (4). Four sensors are used in the Occupant Classification System (OCS). The sensors are located below the seat cushion between the seat adjuster track and the seat adjuster riser at each corner of the passenger side front seat. A threaded mounting stud (2) on each sensor body is secured by a nut to the seat adjuster riser, and two nuts secure each sensor mounting flange (1) to two studs integral to the front and rear of the inboard and outboard passenger side lower seat adjuster tracks. A molded connector receptacle (3) integral to each sensor body is oriented towards the center of the seat and is connected to the vehicle electrical system through a dedicated connector and take out of the passenger seat wire harness beneath the seat cushion. The seat weight sensors cannot be adjusted or repaired and, if faulty or damaged, the entire sensor must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Description and Operation > Description > Page 8019 Seat Occupant Sensor: Description and Operation Operation OPERATION The seat weight sensor units are designed to sense the relative weight of a load applied to the passenger side front seat, which provides a logic input to the microprocessor of the Occupant Classification Module (OCM). When any load is applied to the seat the load is transmitted through the sensor mounting flange to the sensor body (strain gauge) of each sensor, causing a change of electrical resistance through the strain gauge. These changes in resistance within the internal sensor circuitry change the sensor output voltage. Each weight sensor receives a nominal five volts and a clean ground through parallel hard wired circuits from the OCM. The OCM then monitors the output voltage of each sensor on dedicated hard wired data communication circuits. The hard wired circuits between the sensors and the OCM may be diagnosed and tested using conventional diagnostic tools and procedures. However, the most reliable, efficient, and accurate means to diagnose the seat weight sensor inputs to the OCM, and the electronic message communication between the OCM and the Occupant Restraint Controller (ORC) requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Service and Repair > Removal Seat Occupant Sensor: Service and Repair Removal REMOVAL WARNING: To avoid personal injury or death, never strike or drop a seat weight sensor or the passenger side front seat assembly to which the sensors are secured as it can damage the sensors or affect their calibration. The seat weight sensors and the passenger side front seat assembly must be handled with care to avoid damage to the sensors. Do not sit upon or place any loads upon a passenger side front seat while it is removed from its mounts in or outside of the vehicle. If an individual sensor is dropped or damaged, replace the sensor with a new and unused unit. If a seat has been dropped during removal or loaded while removed from its mounts, replace each of the seat weight sensors with new and unused units. Failure to observe this warning could result in an accidental, incomplete, or improper passenger side front supplemental restraint deployment. 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the system reserve capacitor to discharge before servicing any airbag components. 2. Remove the passenger front seat from the vehicle as a unit. CAUTION: Strain gauge alignment tool 9689 (2) must be used to secure the body of the seat weight sensor (1) from any rotation during removal or installation of the nut that secures the sensor stud to the seat adjuster riser. In addition, the sensor fasteners should always be serviced using hand tools ONLY, and not electric or pneumatic power tools. Failure to observe these precautions may result in irreversible sensor damage and require sensor replacement. 3. Remove the passenger front seat riser from the seat. 4. Disconnect each weight sensor electrical connector and install strain gauge alignment tool 9689. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Service and Repair > Removal > Page 8022 5. Insert the fork (1) into weight sensor and seat the support yoke (2) firmly against the weight sensor cage. 6. Remove center stud nut and repeat these steps for each of the four weight sensors. 7. Separate the seat track from the seat risers. 8. Remove the nuts securing the seat weight sensor to the adjuster track and remove the seat weight sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Service and Repair > Removal > Page 8023 Seat Occupant Sensor: Service and Repair Installation INSTALLATION WARNING: To avoid personal injury or death, never strike or drop a seat weight sensor or the passenger side front seat assembly to which the sensors are secured as it can damage the sensors or affect their calibration. The seat weight sensors and the passenger side front seat assembly must be handled with care to avoid damage to the sensors. Do not sit upon or place any loads upon a passenger side front seat while it is removed from its mounts in or outside of the vehicle. If an individual sensor is dropped or damaged, replace the sensor with a new and unused unit. If a seat has been dropped during removal or loaded while removed from its mounts, replace each of the seat weight sensors with new and unused units. Failure to observe this warning could result in an accidental, incomplete, or improper passenger side front supplemental restraint deployment. WARNING: To avoid personal injury or death on vehicles equipped with the Occupant Classification System (OCS), any time the passenger side front seat assembly has been removed or loosened from the vehicle for service of any vehicle component or system the Occupant Classification System Verification Test must be performed using a diagnostic scan tool and the Occupant Classification Seat Weight special tool following reinstallation. Refer to the appropriate diagnostic procedures. Failure to observe this warning could result in an accidental, incomplete, or improper passenger side front supplemental restraint deployment. CAUTION: Strain gauge alignment tool 9689 (2) must be used to secure the body of the seat weight sensor (1) from any rotation during removal or installation of the nut that secures the sensor stud to the seat adjuster riser. In addition, the sensor fasteners should always be serviced using hand tools ONLY, and not electric or pneumatic power tools. Failure to observe these precautions may result in irreversible sensor damage and require sensor replacement. 1. Install the seat weight sensor and install the nuts securing the seat weight sensor to the adjuster track. Tighten nuts to 28 Nm (21 ft. lbs.). 2. Place the seat track onto the seat riser. 3. Install the nut on the center stud and repeat for each of the four weight sensors. CAUTION: Do not tighten the center nut to the seat weight sensors without the use of strain gauge alignment tool 9689. 4. Insert the fork (1) into weight sensor and seat the support yoke (2) firmly against the weight sensor cage. Tighten nut to 45 Nm (33 ft. lbs.). Repeat for all four sensors. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Service and Repair > Removal > Page 8024 5. Connect each weight sensor electrical connector. 6. Reinstall the passenger front seat. WARNING: Do not connect the battery negative cable. Personal injury or death may result if the system test is not performed first. WARNING: Following successful completion of the Airbag System verification test procedure, perform the Occupant Classification System Verification Test using a diagnostic scan tool and the Occupant Classification Seat Weight special tool 9077. Refer to the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver Seat Sensor/Switch: Locations Sensor-Seat Track Position-Driver Component ID: 306 Component : SENSOR-SEAT TRACK POSITION-DRIVER Connector: Name : SENSOR-SEAT TRACK POSITION-DRIVER Color : DK. GRAY # of pins : 2 Pin Description Circuit 1 DRIVER SEAT POSITION SENSOR DATA R261 20LB/WT 2 DRIVER SEAT POSITION SENSOR VOLTAGER263 20LB/VT Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 8029 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 8030 Seat Sensor/Switch: Locations Sensor-Seat Track Position-Passenger Component ID: 307 Component : SENSOR-SEAT TRACK POSITION-PASSENGER Connector: Name : SENSOR-SEAT TRACK POSITION-PASSENGER Color : DK. GRAY # of pins : 2 Pin Description Circuit 1 PASSENGER SEAT POSITION SENSOR DATAR262 20WT/LB 2 PASSENGER SEAT POSITION SENSOR VOLTAGE R264 20VT/LB Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 8031 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 8032 Seat Sensor/Switch: Locations Sensor-Seat Weight-Left Front Component ID: 308 Component : SENSOR-SEAT WEIGHT-LEFT FRONT Connector: Name : SENSOR-SEAT WEIGHT-LEFT FRONT Color : BLACK # of pins : 3 Pin Description Circuit 1 SEAT WEIGHT SENSOR GROUND R728 20LB/YL 2 SEAT WEIGHT LEFT FRONT SENSOR SIGNAL R717 20LG/DG 3 SEAT WEIGHT SENSOR 5 VOLT R701 20LG Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 8033 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 8034 Seat Sensor/Switch: Locations Sensor-Seat Weight-Left Rear Component ID: 309 Component : SENSOR-SEAT WEIGHT-LEFT REAR Connector: Name : SENSOR-SEAT WEIGHT-LEFT REAR Color : BLACK # of pins : 3 Pin Description Circuit 1 SEAT WEIGHT SENSOR GROUND R728 20LB/YL 2 SEAT WEIGHT LEFT REAR SENSOR SIGNALR705 20LG/OR 3 SEAT WEIGHT SENSOR 5 VOLT R701 20LG Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 8035 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 8036 Seat Sensor/Switch: Locations Sensor-Seat Track Position-Driver Component ID: 306 Component : SENSOR-SEAT TRACK POSITION-DRIVER Connector: Name : SENSOR-SEAT TRACK POSITION-DRIVER Color : DK. GRAY # of pins : 2 Pin Description Circuit 1 DRIVER SEAT POSITION SENSOR DATA R261 20LB/WT 2 DRIVER SEAT POSITION SENSOR VOLTAGER263 20LB/VT Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 8037 Sensor-Seat Track Position-Passenger Component ID: 307 Component : SENSOR-SEAT TRACK POSITION-PASSENGER Connector: Name : SENSOR-SEAT TRACK POSITION-PASSENGER Color : DK. GRAY # of pins : 2 Pin Description Circuit Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 8038 1 PASSENGER SEAT POSITION SENSOR DATAR262 20WT/LB 2 PASSENGER SEAT POSITION SENSOR VOLTAGE R264 20VT/LB Component Location - 57 Sensor-Seat Weight-Left Front Component ID: 308 Component : SENSOR-SEAT WEIGHT-LEFT FRONT Connector: Name : SENSOR-SEAT WEIGHT-LEFT FRONT Color : BLACK # of pins : 3 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 8039 Pin Description Circuit 1 SEAT WEIGHT SENSOR GROUND R728 20LB/YL 2 SEAT WEIGHT LEFT FRONT SENSOR SIGNAL R717 20LG/DG 3 SEAT WEIGHT SENSOR 5 VOLT R701 20LG Component Location - 57 Sensor-Seat Weight-Left Rear Component ID: 309 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 8040 Component : SENSOR-SEAT WEIGHT-LEFT REAR Connector: Name : SENSOR-SEAT WEIGHT-LEFT REAR Color : BLACK # of pins : 3 Pin Description Circuit 1 SEAT WEIGHT SENSOR GROUND R728 20LB/YL 2 SEAT WEIGHT LEFT REAR SENSOR SIGNALR705 20LG/OR 3 SEAT WEIGHT SENSOR 5 VOLT R701 20LG Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 8041 Sensor-Seat Weight-Right Front Component ID: 310 Component : SENSOR-SEAT WEIGHT-RIGHT FRONT Connector: Name : SENSOR-SEAT WEIGHT-RIGHT FRONT Color : BLACK # of pins : 3 Pin Description Circuit Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 8042 1 SEAT WEIGHT SENSOR GROUND R728 20LB/YL 2 SEAT WEIGHT RIGHT FRONT SENSOR SIGNAL R718 20LB/DG 3 SEAT WEIGHT SENSOR 5 VOLT R701 20LG Component Location - 57 Sensor-Seat Weight-Right Rear Component ID: 311 Component : SENSOR-SEAT WEIGHT-RIGHT REAR Connector: Name : SENSOR-SEAT WEIGHT-RIGHT REAR Color : BLACK # of pins : 3 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 8043 Pin Description Circuit 1 SEAT WEIGHT SENSOR GROUND R728 20LB/YL 2 SEAT WEIGHT RIGHT REAR SENSOR SIGNAL R706 20LB/OR 3 SEAT WEIGHT SENSOR 5 VOLT R701 20LG Component Location - 57 Switch-Seat Belt-Driver Component ID: 355 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 8044 Component : SWITCH-SEAT BELT-DRIVER Connector: Name : SWITCH-SEAT BELT-DRIVER Color : BLACK # of pins : 2 Pin Description Circuit 1 DRIVER SEAT BELT SWITCH SENSE R57 20LG/GY 2 GROUND Z961 20BK/YL Component Location - 48 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 8045 Switch-Seat Belt-Passenger Component ID: 356 Component : SWITCH-SEAT BELT-PASSENGER Connector: Name : SWITCH-SEAT BELT-PASSENGER Color : WHITE # of pins : 2 Pin Description Circuit Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Sensor-Seat Track Position-Driver > Page 8046 1 PASSENGER HALL EFFECT (+) R274 20LB/WT 2 PASSENGER HALL EFFECT (-) R272 20LB/VT Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver Seat Sensor/Switch: Diagrams Sensor-Seat Track Position-Driver Component ID: 306 Component : SENSOR-SEAT TRACK POSITION-DRIVER Connector: Name : SENSOR-SEAT TRACK POSITION-DRIVER Color : DK. GRAY # of pins : 2 Pin Description Circuit 1 DRIVER SEAT POSITION SENSOR DATA R261 20LB/WT 2 DRIVER SEAT POSITION SENSOR VOLTAGER263 20LB/VT Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 8049 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 8050 Seat Sensor/Switch: Diagrams Sensor-Seat Track Position-Passenger Component ID: 307 Component : SENSOR-SEAT TRACK POSITION-PASSENGER Connector: Name : SENSOR-SEAT TRACK POSITION-PASSENGER Color : DK. GRAY # of pins : 2 Pin Description Circuit 1 PASSENGER SEAT POSITION SENSOR DATAR262 20WT/LB 2 PASSENGER SEAT POSITION SENSOR VOLTAGE R264 20VT/LB Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 8051 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 8052 Seat Sensor/Switch: Diagrams Sensor-Seat Weight-Left Front Component ID: 308 Component : SENSOR-SEAT WEIGHT-LEFT FRONT Connector: Name : SENSOR-SEAT WEIGHT-LEFT FRONT Color : BLACK # of pins : 3 Pin Description Circuit 1 SEAT WEIGHT SENSOR GROUND R728 20LB/YL 2 SEAT WEIGHT LEFT FRONT SENSOR SIGNAL R717 20LG/DG 3 SEAT WEIGHT SENSOR 5 VOLT R701 20LG Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 8053 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 8054 Seat Sensor/Switch: Diagrams Sensor-Seat Weight-Left Rear Component ID: 309 Component : SENSOR-SEAT WEIGHT-LEFT REAR Connector: Name : SENSOR-SEAT WEIGHT-LEFT REAR Color : BLACK # of pins : 3 Pin Description Circuit 1 SEAT WEIGHT SENSOR GROUND R728 20LB/YL 2 SEAT WEIGHT LEFT REAR SENSOR SIGNALR705 20LG/OR 3 SEAT WEIGHT SENSOR 5 VOLT R701 20LG Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 8055 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 8056 Seat Sensor/Switch: Diagrams Sensor-Seat Track Position-Driver Component ID: 306 Component : SENSOR-SEAT TRACK POSITION-DRIVER Connector: Name : SENSOR-SEAT TRACK POSITION-DRIVER Color : DK. GRAY # of pins : 2 Pin Description Circuit 1 DRIVER SEAT POSITION SENSOR DATA R261 20LB/WT 2 DRIVER SEAT POSITION SENSOR VOLTAGER263 20LB/VT Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 8057 Sensor-Seat Track Position-Passenger Component ID: 307 Component : SENSOR-SEAT TRACK POSITION-PASSENGER Connector: Name : SENSOR-SEAT TRACK POSITION-PASSENGER Color : DK. GRAY # of pins : 2 Pin Description Circuit Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 8058 1 PASSENGER SEAT POSITION SENSOR DATAR262 20WT/LB 2 PASSENGER SEAT POSITION SENSOR VOLTAGE R264 20VT/LB Component Location - 57 Sensor-Seat Weight-Left Front Component ID: 308 Component : SENSOR-SEAT WEIGHT-LEFT FRONT Connector: Name : SENSOR-SEAT WEIGHT-LEFT FRONT Color : BLACK # of pins : 3 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 8059 Pin Description Circuit 1 SEAT WEIGHT SENSOR GROUND R728 20LB/YL 2 SEAT WEIGHT LEFT FRONT SENSOR SIGNAL R717 20LG/DG 3 SEAT WEIGHT SENSOR 5 VOLT R701 20LG Component Location - 57 Sensor-Seat Weight-Left Rear Component ID: 309 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 8060 Component : SENSOR-SEAT WEIGHT-LEFT REAR Connector: Name : SENSOR-SEAT WEIGHT-LEFT REAR Color : BLACK # of pins : 3 Pin Description Circuit 1 SEAT WEIGHT SENSOR GROUND R728 20LB/YL 2 SEAT WEIGHT LEFT REAR SENSOR SIGNALR705 20LG/OR 3 SEAT WEIGHT SENSOR 5 VOLT R701 20LG Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 8061 Sensor-Seat Weight-Right Front Component ID: 310 Component : SENSOR-SEAT WEIGHT-RIGHT FRONT Connector: Name : SENSOR-SEAT WEIGHT-RIGHT FRONT Color : BLACK # of pins : 3 Pin Description Circuit Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 8062 1 SEAT WEIGHT SENSOR GROUND R728 20LB/YL 2 SEAT WEIGHT RIGHT FRONT SENSOR SIGNAL R718 20LB/DG 3 SEAT WEIGHT SENSOR 5 VOLT R701 20LG Component Location - 57 Sensor-Seat Weight-Right Rear Component ID: 311 Component : SENSOR-SEAT WEIGHT-RIGHT REAR Connector: Name : SENSOR-SEAT WEIGHT-RIGHT REAR Color : BLACK # of pins : 3 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 8063 Pin Description Circuit 1 SEAT WEIGHT SENSOR GROUND R728 20LB/YL 2 SEAT WEIGHT RIGHT REAR SENSOR SIGNAL R706 20LB/OR 3 SEAT WEIGHT SENSOR 5 VOLT R701 20LG Component Location - 57 Switch-Seat Belt-Driver Component ID: 355 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 8064 Component : SWITCH-SEAT BELT-DRIVER Connector: Name : SWITCH-SEAT BELT-DRIVER Color : BLACK # of pins : 2 Pin Description Circuit 1 DRIVER SEAT BELT SWITCH SENSE R57 20LG/GY 2 GROUND Z961 20BK/YL Component Location - 48 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 8065 Switch-Seat Belt-Passenger Component ID: 356 Component : SWITCH-SEAT BELT-PASSENGER Connector: Name : SWITCH-SEAT BELT-PASSENGER Color : WHITE # of pins : 2 Pin Description Circuit Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 8066 1 PASSENGER HALL EFFECT (+) R274 20LB/WT 2 PASSENGER HALL EFFECT (-) R272 20LB/VT Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Service and Repair > Removal Antenna, Navigation: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel top cover. 3. Remove the radio (4). 4. Remove the antenna (1) mounting fasteners 5. Remove antenna cable (3) from wire harness. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Service and Repair > Removal > Page 8073 Antenna, Navigation: Service and Repair Installation INSTALLATION 1. Position antenna cable (3) to wire harness. Secure into place. 2. Install antenna (1) mounting fasteners. 3. Install radio (4). 4. Install instrument panel top cover. 5. Connect battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Description and Operation Antenna Cable: Description and Operation DESCRIPTION The satellite radio antenna cable connects the roof mounted antenna to the satellite receiver module. It has two connectors at each end and is routed above the headliner, then behind the left quarter panel trim. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Removal Antenna Cable: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the rear quarter trim panel. 3. Lower the rear portion of the headliner as necessary to access the underside of the satellite antenna. 4. Detach the antenna cable (1) from the body harness. Disconnect wire harness connectors at each end of the cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Removal > Page 8080 Antenna Cable: Service and Repair Installation INSTALLATION 1. Secure the antenna cable (1) to the body harness. Connect the wire harness connectors at each end of the antenna. 2. Install the headliner. 3. Install the rear quarter trim panel. 4. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations Alarm Module: Locations Component ID: 156 Component : MODULE-INTRUSION TRANSCEIVER Connector: Name : MODULE-INTRUSION TRANSCEIVER C1 Color : BLACK # of pins : 6 Pin Description Circuit 1 FUSED B(+) (I.O.D.) A415 20RD/TN 2-3 CAN B BUS (+) D55 20WT/OR 4 CAN B BUS (-) D54 20WT/PK 5 SIREN SIGNAL CONTROL D96 20WT/BR 6 GROUND Z941 20BK/WT Component Location - 41 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 8085 Component Location - 43 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 8086 Connector: Name : MODULE-INTRUSION TRANSCEIVER C2 Color : BLACK # of pins : 3 Pin Description Circuit 1-2 COURTESY LAMPS DRIVER M24 20YL/WT 3 GROUND Z941 20BK/WT Component Location - 41 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 8087 Component Location - 43 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 8088 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 8089 Alarm Module: Diagrams Component ID: 156 Component : MODULE-INTRUSION TRANSCEIVER Connector: Name : MODULE-INTRUSION TRANSCEIVER C1 Color : BLACK # of pins : 6 Pin Description Circuit 1 FUSED B(+) (I.O.D.) A415 20RD/TN 2-3 CAN B BUS (+) D55 20WT/OR 4 CAN B BUS (-) D54 20WT/PK 5 SIREN SIGNAL CONTROL D96 20WT/BR 6 GROUND Z941 20BK/WT Component Location - 41 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 8090 Component Location - 43 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 8091 Connector: Name : MODULE-INTRUSION TRANSCEIVER C2 Color : BLACK # of pins : 3 Pin Description Circuit 1-2 COURTESY LAMPS DRIVER M24 20YL/WT 3 GROUND Z941 20BK/WT Component Location - 41 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 8092 Component Location - 43 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 8093 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Description and Operation > Description Alarm System Transponder: Description and Operation Description DESCRIPTION Each ignition key (2) used in the Sentry Key Remote Entry System (SKREES) has a transponder chip included on the circuit board (4) beneath the cover (1) of the integral Remote Keyless Entry (RKE) transmitter (3). In addition to having to be cut to match the mechanical coding of the ignition lock cylinder and programmed for operation of the RKE system, each new Sentry Key has a unique transponder identification code that is permanently programmed into it by the manufacturer, and which must be programmed into the Sentry Key Remote Entry Module (SKREEM), sometimes referred to as the Wireless Control Module (WCM), to be recognized by the SKREES as a valid key. The Sentry Key transponder cannot be adjusted or repaired. If faulty or damaged, the entire key and RKE transmitter unit must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Description and Operation > Description > Page 8098 Alarm System Transponder: Description and Operation Operation OPERATION When the ignition switch is turned to the On position, the Sentry Key REmote Entry Module (SKREEM), sometimes referred to as the Wireless Control Module (WCM), communicates through its antenna with the Sentry Key transponder using a Radio Frequency (RF) signal. The SKREEM/WCM then listens for a RF response from the transponder through the same antenna. The Sentry Key transponder chip is within the range of the SKREEM/WCM transceiver antenna ring when it is inserted into the ignition lock cylinder. The SKREEM/WCM determines whether a valid key is present in the ignition lock cylinder based upon the response from the transponder. If a valid key is detected, that fact is communicated by the SKREEM/WCM to the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus, and the PCM allows the engine to continue running. If the PCM receives an invalid key message, or receives no message from the SKREEM/WCM over the CAN data bus, the engine will be disabled after about two seconds of operation. The Electromechanical Instrument Cluster (EMIC), sometimes referred to as the Cab Compartment Node (CCN), will also respond to the invalid key message on the CAN data bus by flashing the security indicator on and off. Each Sentry Key has a unique transponder identification code permanently programmed into it by the manufacturer. Likewise, the SKREEM/WCM has a unique Secret Key code programmed into it by the manufacturer. When a Sentry Key is programmed into the memory of the SKREEM/WCM, the SKREEM/WCM stores the transponder identification code from the Sentry Key, and the Sentry Key learns the Secret Key code from the SKREEM/WCM. Once the Sentry Key learns the Secret Key code of the SKREEM/WCM, it is permanently stored in the memory of the transponder. Therefore, once a Sentry Key has been programmed to a particular vehicle, it cannot be used on any other vehicle. The Sentry Key REmote Entry System (SKREES) performs a self-test each time the ignition switch is turned to the On position, and will store key-related fault information in the form of a Diagnostic Trouble Code (DTC) in SKREEM/WCM memory if a Sentry Key transponder problem is detected. The Sentry Key transponder chip can be diagnosed, and any stored DTC can be retrieved using a diagnostic scan tool. Refer to the appropriate diagnostic information. Common communication problems: - Two transponder keys too close together. - Speed Pass too close to transponder key. - Loss of PCM communication. - Failed antenna circuit. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Component ID: 161 Component : MODULE-SENTRY KEY REMOTE ENTRY/WCM Connector: Name : MODULE-SENTRY KEY REMOTE ENTRY/WCM Color : BLACK # of pins : 8 Pin Description Circuit 1 IGNITION SWITCH SENSE G20 20VT/BR 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4 GROUND Z937 20BK/YL 5 FUSED B(+) (I.O.D.) A411 20RD/LG 6 CAN B BUS (+) D55 20WT/OR 7 CAN B BUS (-) D54 20WT/PK 8-Component Location - 28 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 8103 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 8104 Keyless Entry Module: Diagrams Component ID: 161 Component : MODULE-SENTRY KEY REMOTE ENTRY/WCM Connector: Name : MODULE-SENTRY KEY REMOTE ENTRY/WCM Color : BLACK # of pins : 8 Pin Description Circuit 1 IGNITION SWITCH SENSE G20 20VT/BR 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4 GROUND Z937 20BK/YL 5 FUSED B(+) (I.O.D.) A411 20RD/LG 6 CAN B BUS (+) D55 20WT/OR 7 CAN B BUS (-) D54 20WT/PK 8-Component Location - 28 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 8105 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Description and Operation > Description Keyless Entry Module: Description and Operation Description DESCRIPTION When a PCM and the SKREEM are replaced at the same time, perform the following steps in order: 1. Program the new PCM. 2. Program the new SKREEM. 3. Replace all ignition keys and program them to the new SKREEM. The Sentry Key REmote Entry Module (SKREEM) is sometimes referred to as the Wireless Control Module (WCM). The SKREEM/WCM is the primary component of the Sentry Key Immobilizer System (SKIS). It is also the receiver for the Remote Keyless Entry (RKE) system and the Tire Pressure Monitor (TPM) system. The SKREEM/WCM is located on the steering column, around the ignition lock cylinder housing and is concealed beneath the steering column shrouds. The molded black plastic housing for the SKREEM/WCM has an integral molded plastic halo-like antenna ring (3) that extends from one side. When the SKREEM/WCM is properly installed, the antenna ring is oriented around the ignition lock cylinder housing. A single connector (4) is located next to the antenna ring on the SKREEM/WCM housing (3). A molded plastic mounting tab (2) on the SKREEM/WCM housing secures the unit to the steering column. The SKREEM/WCM is connected to the vehicle electrical system through the instrument panel wire harness. The SKREEM/WCM cannot be adjusted or repaired. If faulty or damaged, the entire SKREEM unit must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Description and Operation > Description > Page 8108 Keyless Entry Module: Description and Operation Operation OPERATION The Sentry Key REmote Entry Module (SKREEM), sometimes referred to as the Wireless Control Module (WCM), contains a Radio Frequency (RF) transceiver and a microprocessor. The SKREEM/WCM transmits RF signals to, and receives RF signals from the Sentry Key transponder through a tuned antenna enclosed within the molded plastic antenna ring integral to the SKREEM/WCM housing. If this antenna ring is not mounted properly around the ignition lock cylinder housing, communication problems between the SKREEM/WCM and the transponder may arise. These communication problems will result in Sentry Key transponder-related faults. The SKREEM also serves as the Remote Keyless Entry (RKE) RF receiver and, if the vehicle is so equipped, the receiver for the Tire Pressure Monitoring (TPM) system. The SKREEM/WCM communicates over the Controller Area Network (CAN) data bus with the Electromechanical Instrument Cluster (EMIC) (sometimes referred to as the Cab Compartment Node (CCN), the Powertrain Control Module (PCM), and/or the diagnostic scan tool. The SKREEM/WCM retains in memory the ID numbers of any Sentry Key transponder that is programmed into it. A maximum of eight Sentry Key transponders can be programmed into the SKREEM/WCM. For added system security, each SKREEM/WCM is programmed with a unique Secret Key code. This code is stored in memory, sent over the CAN data bus to the PCM, and is encoded to the transponder of every Sentry Key that is programmed into the SKREEM/WCM. Therefore, the Secret Key code is a common element that is found in every component of the Sentry Key Immobilizer System (SKIS). Another security code, called a PIN, is used to gain access to the SKREEM/WCM Secured Access Mode. The Secured Access Mode is required during service to perform the SKIS initialization and Sentry Key transponder programming procedures. The SKREEM/WCM also stores the Vehicle Identification Number (VIN) in its memory, which it learns through a CAN data bus message from the PCM during SKIS initialization. NOTE: After a SKREEM/WCM is replaced, the ignition/transponder keys need to be programmed to the new SKREEM/WCM. Follow the directions on the diagnostic scan tool. The transponder key for the SKREES/SKIM and the RKE will both be programmed during this operation. There is no need to program the fob of the key for RKE functionality once the transponder key is programmed to the new SKREEM/WCM. In the event that a SKREEM/WCM replacement is required, the Secret Key code can be transferred to the new SKREEM/WCM from the PCM using the diagnostic scan tool and the SKIS initialization procedure. Proper completion of the SKIS initialization will allow the existing Sentry Keys to be programmed into the new SKREEM/WCM so that new keys will not be required. In the event that the original Secret Key code cannot be recovered, SKREEM/WCM replacement will also require new Sentry Keys. The diagnostic scan tool will alert the technician during the SKIS initialization procedure if new Sentry Keys are required. When the ignition switch is turned to the On position, the SKREEM/WCM transmits an RF signal to the transponder in the ignition key. The SKREEM/WCM then waits for an RF signal response from the transponder. If the response received identifies the key as valid, the SKREEM/WCM sends a valid key message to the PCM over the CAN data bus. If the response received identifies the key as invalid or if no response is received from the key transponder, the SKREEM/WCM sends an invalid key message to the PCM. The PCM will enable or disable engine operation based upon the status of the SKREEM/WCM messages. It is important to note that the default condition in the PCM is an invalid key; therefore, if no message is received from the SKREEM/WCM by the PCM, the engine will be disabled and the vehicle immobilized after two seconds of running. The SKREEM/WCM also sends security indicator status messages to the EMIC/CCN over the CAN data bus to tell the EMIC/CCN how to operate the security indicator. The security indicator status message from the SKREEM/WCM tells the EMIC/CCN to turn the indicator on for about three seconds each time the ignition switch is turned to the On position as a bulb test. After completion of the bulb test, the SKREEM/WCM sends security indicator status messages to the EMIC/CCN to turn the indicator off, turn the indicator on, or to flash the indicator on and off. If the security indicator flashes or stays on solid after the bulb test, it signifies a SKIS fault. If the SKREEM/WCM detects a system malfunction and/or the SKIS has become inoperative, the security indicator will stay on solid. If the SKREEM/WCM detects an invalid key or if a key transponder-related fault exists, the security indicator will flash. If the vehicle is equipped with the Customer Learn transponder programming feature, the SKREEM/WCM will also send messages to the EMIC/CCN to flash the security indicator whenever the Customer Learn programming mode is being utilized. The SKIS performs a self-test each time the ignition switch is turned to the On position, and will store fault information in the form of a Diagnostic Trouble Code (DTC) in SKREEM/WCM memory if a system malfunction is detected. The SKREEM/WCM can be diagnosed, and any stored DTC can be retrieved using a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Description and Operation > Page 8109 Keyless Entry Module: Testing and Inspection REMOTE KEYLESS ENTRY MODULE The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic information. Refer to the appropriate wiring information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair > Removal Keyless Entry Module: Service and Repair Removal REMOVAL NOTE: The steering wheel does not have to be removed to service the SKREEM/WCM. NOTE: The Steering Column Control Module (SCCM) assembly, which consists of the left/right multi-function switches and the clockspring, does not have to be removed to service the SKREEM/WCM. There is an access hole in the top of the right multi-function switch to access the mounting screw (2). 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. 2. Remove the upper and lower steering column shrouds. 3. Remove the SKREEM/WCM mounting screw (2) on the ignition lock assembly and separate the SKREEM/WCM (3) from the ignition lock assembly. 4. Disconnect the SKREEM/WCM electrical connector (4). 5. Remove SKREEM/WCM (1 and 3) from column (2). When a PCM and the SKREEM/WCM are replaced at the same time, perform the following steps in order. - Program the new PCM. - Program the new SKREEM/WCM. - Replace all ignition keys and program them to the new SKREEM/WCM. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair > Removal > Page 8112 Keyless Entry Module: Service and Repair Installation INSTALLATION When a PCM and the SKREEM/WCM are replaced at the same time, perform the following steps in order. - Program the new PCM. - Program the new SKREEM/WCM. - Replace all ignition keys and program them to the new SKREEM/WCM. 1. Position the SKREEM/WCM (3) on the ignition lock housing and install the retaining screw (2). 2. Connect the SKREEM/WCM electrical connector (4). NOTE: On vehicles equipped with the optional Sentry Key Immobilizer System (SKIS), when the SKREEM is replaced with a new unit, a diagnostic scan tool MUST be used to initialize the new SKREEM and to program at least two Sentry Key transponders before the vehicle can be operated. 3. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > System Information > Technical Service Bulletins > Customer Interest for Keyless Starting System: > 08-018-07 > Jun > 07 > Remote Start System - RKE Inop/Alarm Sounds Keyless Starting System: Customer Interest Remote Start System - RKE Inop/Alarm Sounds NUMBER: 08-018-07 GROUP: Electrical DATE: June 23, 2007 SUBJECT: Mopar Remote Start System - RKE - Intermittent Operation Or Alarm May Sound OVERVIEW: This bulletin involves the installation of a Mopar Remote Start System - Service Repair Kit. MODELS: 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) 2007 (HB/HG) Durango/Aspen 2007 (JK) Wrangler 2008 (J527) Sebring Convertible 2007 (JS) Sebring 2007-2008 (JS) Avenger 2007 (KA) Nitro 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to vehicles installed with a Mopar Remote Start Installation Kit. SYMPTOM/CONDITION: On vehicles that have had a Mopar Remote Start installation Kit installed by a dealer, the customer may experience one or more of the following conditions: A). ON ALL VEHICLES: An intermittent operation of the Remote Keyless Entry (RKE) system. At times, the RKE system may not function as designed. This may include intermittent operation of: lock/unlock mode, remote start mode, or panic mode. The vehicle may be operated manually without issue using the ignition key to open or lock the door, and to start the vehicle. B). ON RAM TRUCK AND DURANGO/ASPEN VEHICLES ONLY: The vehicle alarm may sound when the RKE system is activated by use of the key FOB. Deactivation of the vehicle alarm occurs when the vehicle engine is started using the ignition switch and key. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > System Information > Technical Service Bulletins > Customer Interest for Keyless Starting System: > 08-018-07 > Jun > 07 > Remote Start System - RKE Inop/Alarm Sounds > Page 8121 The above condition(s) may be present ONLY if one of the following specific kit part numbers for the Mopar Remote Start Installation Kit had been installed previously on the suspect vehicle. DIAGNOSIS: If the customer has experienced the above condition, and the vehicle has had a Mopar Remote Start Installation Kit installed, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Install the Remote Start Service Repair Kit. Refer to the detailed instructions included with the repair kit. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > System Information > Technical Service Bulletins > Customer Interest for Keyless Starting System: > 18-018-07 > Jun > 07 > Remote Starting System - RKE, Int. Operation/Alarm Keyless Starting System: Customer Interest Remote Starting System - RKE, Int. Operation/Alarm NUMBER: 18-018-07 GROUP: Electrical DATE: June 23, 2007 SUBJECT: Mopar Remote Start System - RKE - Intermittent Operation Or Alarm May Sound OVERVIEW: This bulletin involves the installation of a Mopar Remote Start System - Service Repair Kit. MODELS: 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) 2007 (HB/HG) Durango/Aspen 2007 (JK) Wrangler 2008 (J527) Sebring Convertible 2007 (JS) Sebring 2007-2008 (JS) Avenger 2007 (KA) Nitro 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to vehicles installed with a Mopar Remote Start Installation Kit. SYMPTOM/CONDITION: On vehicles that have had a Mopar Remote Start installation Kit installed by a dealer, the customer may experience one or more of the following conditions: A). ON ALL VEHICLES: An intermittent operation of the Remote Keyless Entry (RKE) system. At times, the RKE system may not function as designed. This may include intermittent operation of: lock/unlock mode, remote start mode, or panic mode. The vehicle may be operated manually without issue using the ignition key to open or lock the door, and to start the vehicle. B). ON RAM TRUCK AND DURANGO/ASPEN VEHICLES ONLY: The vehicle alarm may sound when the RKE system is activated by use of the key FOB. Deactivation of the vehicle alarm occurs when the vehicle engine is started using the ignition switch and key. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > System Information > Technical Service Bulletins > Customer Interest for Keyless Starting System: > 18-018-07 > Jun > 07 > Remote Starting System - RKE, Int. Operation/Alarm > Page 8126 The above condition(s) may be present ONLY if one of the following specific kit part numbers for the Mopar Remote Start Installation Kit had been installed previously on the suspect vehicle. DIAGNOSIS: If the customer has experienced the above condition, and the vehicle has had a Mopar Remote Start Installation Kit installed, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Install the Remote Start Service Repair Kit. Refer to the detailed instructions included with the repair kit. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > 08-018-07 > Jun > 07 > Remote Start System - RKE Inop/Alarm Sounds Keyless Starting System: All Technical Service Bulletins Remote Start System - RKE Inop/Alarm Sounds NUMBER: 08-018-07 GROUP: Electrical DATE: June 23, 2007 SUBJECT: Mopar Remote Start System - RKE - Intermittent Operation Or Alarm May Sound OVERVIEW: This bulletin involves the installation of a Mopar Remote Start System - Service Repair Kit. MODELS: 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) 2007 (HB/HG) Durango/Aspen 2007 (JK) Wrangler 2008 (J527) Sebring Convertible 2007 (JS) Sebring 2007-2008 (JS) Avenger 2007 (KA) Nitro 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to vehicles installed with a Mopar Remote Start Installation Kit. SYMPTOM/CONDITION: On vehicles that have had a Mopar Remote Start installation Kit installed by a dealer, the customer may experience one or more of the following conditions: A). ON ALL VEHICLES: An intermittent operation of the Remote Keyless Entry (RKE) system. At times, the RKE system may not function as designed. This may include intermittent operation of: lock/unlock mode, remote start mode, or panic mode. The vehicle may be operated manually without issue using the ignition key to open or lock the door, and to start the vehicle. B). ON RAM TRUCK AND DURANGO/ASPEN VEHICLES ONLY: The vehicle alarm may sound when the RKE system is activated by use of the key FOB. Deactivation of the vehicle alarm occurs when the vehicle engine is started using the ignition switch and key. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > 08-018-07 > Jun > 07 > Remote Start System - RKE Inop/Alarm Sounds > Page 8132 The above condition(s) may be present ONLY if one of the following specific kit part numbers for the Mopar Remote Start Installation Kit had been installed previously on the suspect vehicle. DIAGNOSIS: If the customer has experienced the above condition, and the vehicle has had a Mopar Remote Start Installation Kit installed, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Install the Remote Start Service Repair Kit. Refer to the detailed instructions included with the repair kit. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > 18-018-07 > Jun > 07 > Remote Starting System - RKE, Int. Operation/Alarm Keyless Starting System: All Technical Service Bulletins Remote Starting System - RKE, Int. Operation/Alarm NUMBER: 18-018-07 GROUP: Electrical DATE: June 23, 2007 SUBJECT: Mopar Remote Start System - RKE - Intermittent Operation Or Alarm May Sound OVERVIEW: This bulletin involves the installation of a Mopar Remote Start System - Service Repair Kit. MODELS: 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) 2007 (HB/HG) Durango/Aspen 2007 (JK) Wrangler 2008 (J527) Sebring Convertible 2007 (JS) Sebring 2007-2008 (JS) Avenger 2007 (KA) Nitro 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to vehicles installed with a Mopar Remote Start Installation Kit. SYMPTOM/CONDITION: On vehicles that have had a Mopar Remote Start installation Kit installed by a dealer, the customer may experience one or more of the following conditions: A). ON ALL VEHICLES: An intermittent operation of the Remote Keyless Entry (RKE) system. At times, the RKE system may not function as designed. This may include intermittent operation of: lock/unlock mode, remote start mode, or panic mode. The vehicle may be operated manually without issue using the ignition key to open or lock the door, and to start the vehicle. B). ON RAM TRUCK AND DURANGO/ASPEN VEHICLES ONLY: The vehicle alarm may sound when the RKE system is activated by use of the key FOB. Deactivation of the vehicle alarm occurs when the vehicle engine is started using the ignition switch and key. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > 18-018-07 > Jun > 07 > Remote Starting System - RKE, Int. Operation/Alarm > Page 8137 The above condition(s) may be present ONLY if one of the following specific kit part numbers for the Mopar Remote Start Installation Kit had been installed previously on the suspect vehicle. DIAGNOSIS: If the customer has experienced the above condition, and the vehicle has had a Mopar Remote Start Installation Kit installed, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Install the Remote Start Service Repair Kit. Refer to the detailed instructions included with the repair kit. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > Page 8138 Keyless Starting System: By Symptom Technical Service Bulletin # 18-018-07 Date: 070623 Remote Starting System - RKE, Int. Operation/Alarm NUMBER: 18-018-07 GROUP: Electrical DATE: June 23, 2007 SUBJECT: Mopar Remote Start System - RKE - Intermittent Operation Or Alarm May Sound OVERVIEW: This bulletin involves the installation of a Mopar Remote Start System - Service Repair Kit. MODELS: 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) 2007 (HB/HG) Durango/Aspen 2007 (JK) Wrangler 2008 (J527) Sebring Convertible 2007 (JS) Sebring 2007-2008 (JS) Avenger 2007 (KA) Nitro 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to vehicles installed with a Mopar Remote Start Installation Kit. SYMPTOM/CONDITION: On vehicles that have had a Mopar Remote Start installation Kit installed by a dealer, the customer may experience one or more of the following conditions: A). ON ALL VEHICLES: An intermittent operation of the Remote Keyless Entry (RKE) system. At times, the RKE system may not function as designed. This may include intermittent operation of: lock/unlock mode, remote start mode, or panic mode. The vehicle may be operated manually without issue using the ignition key to open or lock the door, and to start the vehicle. B). ON RAM TRUCK AND DURANGO/ASPEN VEHICLES ONLY: The vehicle alarm may sound when the RKE system is activated by use of the key FOB. Deactivation of the vehicle alarm occurs when the vehicle engine is started using the ignition switch and key. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > Page 8139 The above condition(s) may be present ONLY if one of the following specific kit part numbers for the Mopar Remote Start Installation Kit had been installed previously on the suspect vehicle. DIAGNOSIS: If the customer has experienced the above condition, and the vehicle has had a Mopar Remote Start Installation Kit installed, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Install the Remote Start Service Repair Kit. Refer to the detailed instructions included with the repair kit. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 08-018-07 Date: 070623 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > Page 8140 Remote Start System - RKE Inop/Alarm Sounds NUMBER: 08-018-07 GROUP: Electrical DATE: June 23, 2007 SUBJECT: Mopar Remote Start System - RKE - Intermittent Operation Or Alarm May Sound OVERVIEW: This bulletin involves the installation of a Mopar Remote Start System - Service Repair Kit. MODELS: 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) 2007 (HB/HG) Durango/Aspen 2007 (JK) Wrangler 2008 (J527) Sebring Convertible 2007 (JS) Sebring 2007-2008 (JS) Avenger 2007 (KA) Nitro 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to vehicles installed with a Mopar Remote Start Installation Kit. SYMPTOM/CONDITION: On vehicles that have had a Mopar Remote Start installation Kit installed by a dealer, the customer may experience one or more of the following conditions: A). ON ALL VEHICLES: An intermittent operation of the Remote Keyless Entry (RKE) system. At times, the RKE system may not function as designed. This may include intermittent operation of: lock/unlock mode, remote start mode, or panic mode. The vehicle may be operated manually without issue using the ignition key to open or lock the door, and to start the vehicle. B). ON RAM TRUCK AND DURANGO/ASPEN VEHICLES ONLY: The vehicle alarm may sound when the RKE system is activated by use of the key FOB. Deactivation of the vehicle alarm occurs when the vehicle engine is started using the ignition switch and key. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > Page 8141 The above condition(s) may be present ONLY if one of the following specific kit part numbers for the Mopar Remote Start Installation Kit had been installed previously on the suspect vehicle. DIAGNOSIS: If the customer has experienced the above condition, and the vehicle has had a Mopar Remote Start Installation Kit installed, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Install the Remote Start Service Repair Kit. Refer to the detailed instructions included with the repair kit. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 18-018-07 Date: 070623 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > Page 8142 Remote Starting System - RKE, Int. Operation/Alarm NUMBER: 18-018-07 GROUP: Electrical DATE: June 23, 2007 SUBJECT: Mopar Remote Start System - RKE - Intermittent Operation Or Alarm May Sound OVERVIEW: This bulletin involves the installation of a Mopar Remote Start System - Service Repair Kit. MODELS: 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) 2007 (HB/HG) Durango/Aspen 2007 (JK) Wrangler 2008 (J527) Sebring Convertible 2007 (JS) Sebring 2007-2008 (JS) Avenger 2007 (KA) Nitro 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to vehicles installed with a Mopar Remote Start Installation Kit. SYMPTOM/CONDITION: On vehicles that have had a Mopar Remote Start installation Kit installed by a dealer, the customer may experience one or more of the following conditions: A). ON ALL VEHICLES: An intermittent operation of the Remote Keyless Entry (RKE) system. At times, the RKE system may not function as designed. This may include intermittent operation of: lock/unlock mode, remote start mode, or panic mode. The vehicle may be operated manually without issue using the ignition key to open or lock the door, and to start the vehicle. B). ON RAM TRUCK AND DURANGO/ASPEN VEHICLES ONLY: The vehicle alarm may sound when the RKE system is activated by use of the key FOB. Deactivation of the vehicle alarm occurs when the vehicle engine is started using the ignition switch and key. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > Page 8143 The above condition(s) may be present ONLY if one of the following specific kit part numbers for the Mopar Remote Start Installation Kit had been installed previously on the suspect vehicle. DIAGNOSIS: If the customer has experienced the above condition, and the vehicle has had a Mopar Remote Start Installation Kit installed, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Install the Remote Start Service Repair Kit. Refer to the detailed instructions included with the repair kit. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 08-018-07 Date: 070623 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > Page 8144 Remote Start System - RKE Inop/Alarm Sounds NUMBER: 08-018-07 GROUP: Electrical DATE: June 23, 2007 SUBJECT: Mopar Remote Start System - RKE - Intermittent Operation Or Alarm May Sound OVERVIEW: This bulletin involves the installation of a Mopar Remote Start System - Service Repair Kit. MODELS: 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) 2007 (HB/HG) Durango/Aspen 2007 (JK) Wrangler 2008 (J527) Sebring Convertible 2007 (JS) Sebring 2007-2008 (JS) Avenger 2007 (KA) Nitro 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to vehicles installed with a Mopar Remote Start Installation Kit. SYMPTOM/CONDITION: On vehicles that have had a Mopar Remote Start installation Kit installed by a dealer, the customer may experience one or more of the following conditions: A). ON ALL VEHICLES: An intermittent operation of the Remote Keyless Entry (RKE) system. At times, the RKE system may not function as designed. This may include intermittent operation of: lock/unlock mode, remote start mode, or panic mode. The vehicle may be operated manually without issue using the ignition key to open or lock the door, and to start the vehicle. B). ON RAM TRUCK AND DURANGO/ASPEN VEHICLES ONLY: The vehicle alarm may sound when the RKE system is activated by use of the key FOB. Deactivation of the vehicle alarm occurs when the vehicle engine is started using the ignition switch and key. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > Page 8145 The above condition(s) may be present ONLY if one of the following specific kit part numbers for the Mopar Remote Start Installation Kit had been installed previously on the suspect vehicle. DIAGNOSIS: If the customer has experienced the above condition, and the vehicle has had a Mopar Remote Start Installation Kit installed, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Install the Remote Start Service Repair Kit. Refer to the detailed instructions included with the repair kit. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 18-018-07 Date: 070623 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > Page 8146 Remote Starting System - RKE, Int. Operation/Alarm NUMBER: 18-018-07 GROUP: Electrical DATE: June 23, 2007 SUBJECT: Mopar Remote Start System - RKE - Intermittent Operation Or Alarm May Sound OVERVIEW: This bulletin involves the installation of a Mopar Remote Start System - Service Repair Kit. MODELS: 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) 2007 (HB/HG) Durango/Aspen 2007 (JK) Wrangler 2008 (J527) Sebring Convertible 2007 (JS) Sebring 2007-2008 (JS) Avenger 2007 (KA) Nitro 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to vehicles installed with a Mopar Remote Start Installation Kit. SYMPTOM/CONDITION: On vehicles that have had a Mopar Remote Start installation Kit installed by a dealer, the customer may experience one or more of the following conditions: A). ON ALL VEHICLES: An intermittent operation of the Remote Keyless Entry (RKE) system. At times, the RKE system may not function as designed. This may include intermittent operation of: lock/unlock mode, remote start mode, or panic mode. The vehicle may be operated manually without issue using the ignition key to open or lock the door, and to start the vehicle. B). ON RAM TRUCK AND DURANGO/ASPEN VEHICLES ONLY: The vehicle alarm may sound when the RKE system is activated by use of the key FOB. Deactivation of the vehicle alarm occurs when the vehicle engine is started using the ignition switch and key. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > Page 8147 The above condition(s) may be present ONLY if one of the following specific kit part numbers for the Mopar Remote Start Installation Kit had been installed previously on the suspect vehicle. DIAGNOSIS: If the customer has experienced the above condition, and the vehicle has had a Mopar Remote Start Installation Kit installed, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Install the Remote Start Service Repair Kit. Refer to the detailed instructions included with the repair kit. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 08-018-07 Date: 070623 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > Page 8148 Remote Start System - RKE Inop/Alarm Sounds NUMBER: 08-018-07 GROUP: Electrical DATE: June 23, 2007 SUBJECT: Mopar Remote Start System - RKE - Intermittent Operation Or Alarm May Sound OVERVIEW: This bulletin involves the installation of a Mopar Remote Start System - Service Repair Kit. MODELS: 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) 2007 (HB/HG) Durango/Aspen 2007 (JK) Wrangler 2008 (J527) Sebring Convertible 2007 (JS) Sebring 2007-2008 (JS) Avenger 2007 (KA) Nitro 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to vehicles installed with a Mopar Remote Start Installation Kit. SYMPTOM/CONDITION: On vehicles that have had a Mopar Remote Start installation Kit installed by a dealer, the customer may experience one or more of the following conditions: A). ON ALL VEHICLES: An intermittent operation of the Remote Keyless Entry (RKE) system. At times, the RKE system may not function as designed. This may include intermittent operation of: lock/unlock mode, remote start mode, or panic mode. The vehicle may be operated manually without issue using the ignition key to open or lock the door, and to start the vehicle. B). ON RAM TRUCK AND DURANGO/ASPEN VEHICLES ONLY: The vehicle alarm may sound when the RKE system is activated by use of the key FOB. Deactivation of the vehicle alarm occurs when the vehicle engine is started using the ignition switch and key. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > Page 8149 The above condition(s) may be present ONLY if one of the following specific kit part numbers for the Mopar Remote Start Installation Kit had been installed previously on the suspect vehicle. DIAGNOSIS: If the customer has experienced the above condition, and the vehicle has had a Mopar Remote Start Installation Kit installed, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Install the Remote Start Service Repair Kit. Refer to the detailed instructions included with the repair kit. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service and Repair Keyless Entry Transmitter Battery: Service and Repair STANDARD PROCEDURE - RKE TRANSMITTER BATTERIES The Remote Keyless Entry (RKE) transmitter case snaps open and shut for battery access. To replace the RKE transmitter batteries: 1. Using a thin coin, gently pry at the notch in the center seam of the RKE transmitter case halves near the key ring until the two halves unsnap. 2. Lift the back half of the transmitter case off of the RKE transmitter. 3. Remove the two batteries from the RKE transmitter. 4. Replace the two batteries with new Panasonic 2016, or equivalent. Be certain that the batteries are installed with their polarity correctly oriented. 5. Align the two RKE transmitter case halves with each other, and squeeze them firmly and evenly together until they snap back into place. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Audio System - Speaker Static Noise Cellular Phone: Technical Service Bulletins Audio System - Speaker Static Noise NUMBER: 08-019-06 GROUP: Electrical DATE: May 3, 2006 SUBJECT: Speaker Static MODELS: 2007 (PM) Caliber DISCUSSION: If a cell phone which is turned on is stored in the cubby bin directly below the radio, it may cause static from the speaker(s). This is not a radio or speaker malfunction. The condition may be lessened or eliminated by relocating the cellular phone to another location. Some types of cell phones are known to cause this problem while the phone is turned on and operating in extended range mode. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions Cellular Phone: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: Provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 8160 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 8161 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 8162 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 8163 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 8164 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 8165 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 8166 5. Release the Secondary Terminal Lock, if required (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 8167 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 8168 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 8169 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 8170 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 8171 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 8172 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 8173 Cellular Phone: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 8174 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 8175 STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 8176 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Description and Operation > Description Cellular Phone: Description and Operation Description DESCRIPTION TELECOMMUNICATION The hands-free cellular system on this vehicle uses Bluetooth(TM) technology to provide wireless communication between the operator's compatible cellular telephone and the vehicle's on-board receiver. The system uses voice recognition technology to control operation. The incoming voice is broadcast through the vehicle's radio speakers, automatically overriding any other audio signals on the front speakers when the hands-free system is in use. A microphone in the rearview mirror picks up vehicle occupant's voices. The system will communicate with a telephone that is anywhere within the vehicle. However, covering the hand held phone or the hands-free phone module with a metal object may block the signal. The system will recognize up to seven Bluetooth(TM) cellular phones, each of which is given a spoken identification by the user during the setup process. The system includes Spanish voice recognition in addition to English. Two buttons on the rearview mirror, identified with ISO icons, control the system: A "phone" button turns the system on and off; a "voice recognition" (or "voice command") button prompts the hands-free system to listen for a voice command. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Description and Operation > Description > Page 8179 Cellular Phone: Description and Operation Operation OPERATION TELECOMMUNICATION Two buttons on the rearview mirror, identified with ISO icons, control the system: A "phone" button turns the system on and off; a "voice recognition" (or "voice command") button prompts the hands-free system to listen for a voice command. The system includes the following features: - Phone book - Stores telephone numbers for later recall by name or other verbal identification, called a voice tag, and memory location. - Four memory locations - Home, Work, Cellular and Pager. A maximum of 32 unique names or voice tags may be stored at the same time, with a different number in each of the four memory locations. - Voice tag dialing - Dials the number associated with a voice tag and memory location. - Digit dialing - Dials the telephone number by recognizing the names of the digits as they are spoken. - Receiving calls - A voice prompt notifies the user of an incoming call. A voice response accepts or rejects the call without manual intervention. - Privacy Mode - Switches the call to the handheld telephone and the hands-free system and back again using the "voice recognition" (or "voice command") button and a voice command, if desired. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Description and Operation > Page 8180 Cellular Phone: Testing and Inspection TELECOMMUNICATIONS Any diagnosis of the Telecommunication system should begin with the use of scan tool. For information on the use of the scan tool, refer to the appropriate Diagnostic Service information. For complete circuit diagrams, refer to the appropriate wiring information. WARNING: On vehicles equipped with airbags, refer to electrical, restraints before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Description and Operation > Page 8181 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Description and Operation > Page 8182 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Description and Operation > Page 8183 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Service and Repair > Removal Cellular Phone: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel end cap. 3. Remove the instrument panel steering column cover. 4. Remove the module mounting fasteners. 5. Disconnect the electrical harness connector and remove module. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Service and Repair > Removal > Page 8186 Cellular Phone: Service and Repair Installation INSTALLATION 1. Connect electrical harness connector and position module. 2. Install module mounting fasteners. 3. Install the instrument panel steering column cover. 4. Install the instrument panel end cap. 5. Connect battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions Driver/Vehicle Information Display: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: Provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8191 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8192 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8193 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8194 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8195 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8196 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8197 5. Release the Secondary Terminal Lock, if required (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8198 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8199 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8200 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8201 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8202 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8203 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8204 Driver/Vehicle Information Display: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8205 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8206 STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8207 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8208 Driver/Vehicle Information Display: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-49-02 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8209 8w-49-03 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8210 8w-49-04 Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Description Driver/Vehicle Information Display: Description and Operation Description DESCRIPTION The base instrument cluster can be identified by the single TRIP SHAFT button (18) located to the left of the Temperature Gauge (3). The odometer display (15) doubles as the outside air temperature display when selected by toggling through the odometer menu using the TRIP SHAFT button. The Electronic Vehicle Information Center (EVIC) features a driver-interactive display (29). The display is located in the lower left part of the instrument cluster below the fuel and engine temperature gauges (1 and 3). This system conveniently allows the driver to select a variety of useful information by pressing the STEP button (28) to the right of the EVIC display. The EVIC displays information related to the following: - System Status - Vehicle information warning message displays - Personal Settings (customer programmable features) - Compass display - Outside temperature display - Trip computer functions - U-Connect hands-free communication system displays - If Equipped - Navigation system screens - If Equipped - Audio mode display The EVIC system is comprised of several different components. Those components are: - Instrument Cluster - EVIC STEP Button Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Description > Page 8213 - Ambient Temperature Sensor - Remote Compass Module (RCM) - Controller Area Network (CAN) Data Bus - Local Interface Network (LIN) Data Bus The EVIC display and STEP button are part of the Instrument Cluster assembly and cannot be serviced as separate components. If the display or button are inoperative the complete Instrument Cluster assembly must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Description > Page 8214 Driver/Vehicle Information Display: Description and Operation Operation OPERATION The Electronic Vehicle Information Center (EVIC) uses both non-switched and ignition switched sources of battery current so that some of its features remain operational at any time, while others may only operate with the ignition switch in the On position. When the ignition switch is turned to the On position, the EVIC display (29) will return to the last function being displayed before the ignition was turned to the Off position. The EVIC system is comprised of several different components that communicate over the Controller Area Network (CAN) and Local Interface Network (LIN) Data Buses. If the system is inoperative a scan tool and the appropriate diagnostic information must be used to diagnose the system and related data buses. The instrument cluster STEP button (28) is used to operate the different functions of the EVIC system. Pressing and releasing the STEP button will scroll through the following displays: - Compass/Temperature/Audio - Average Fuel Economy - Distance to Empty - Elapsed Time - Personal Settings Once a particular system is displayed, short and long presses of the STEP button will move the EVIC through the system menu. Pressing and holding the STEP button once will clear the resettable function currently being displayed. Reset will only occur if a resettable function is currently being displayed. To reset all resettable functions, press and release the STEP button a second time within 3 seconds of resetting the currently displayed function (Reset ALL will be displayed during this 3 second window). EVIC DISPLAY MODES SYSTEM STATUS MODE System display mode displays warnings and user interaction messages on the EVIC display (29). The driver can scroll to view multiple messages by using the STEP button. When the appropriate conditions exist, the EVIC displays the following messages: - Turn Signal On (with a continuous warning chime) - Left Front Turn Signal Lamp Out (with a single chime) - Left Rear Turn Signal Lamp Out (with a single chime) - Right Front Turn Signal Lamp Out (with a single chime) - Right Rear Turn Signal Lamp Out (with a single chime) - Personal Settings Not Available - Vehicle Not in Park (automatic transmissions) or vehicle in motion (manual transmissions) - Left/Right Front Door Ajar (one or more, with a single chime if speed is above 1 mph (1.6 km/h)) - Left/Right Rear Door Ajar (one or more, with a single chime if speed is above 1 mph (1.6 km/h)) - Door(s) Ajar (with a single chime if vehicle is in motion) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Description > Page 8215 - Trunk Ajar (with a single chime) - Headlamps On/Lights On With Key Out Of Ignition. COMPASS/TEMPERATURE/AUDIO Compass heading and outside temperature are displayed at the top of the EVIC display screen. On the lower half of the screen the audio mode is displayed along with the odometer. One of eight compass headings to indicate the direction the vehicle is facing (N, S, E, W, NE, NW, SE, SW) and to select one of 15 compass variance settings. Outside temperature is displayed in ° C (degrees Celsius) or ° F (degrees Fahrenheit). Audio mode can display any one of 12 radio station preset frequencies, CD disc number, CD track number, tape, and one of 200 Satellite Radio Channels - if equipped. For information regarding the compass, refer to Personal Settings (Customer Programmable Features). AVERAGE FUEL ECONOMY Shows the average fuel economy since the last reset. When the fuel economy is reset, the display will read "RESET" or show dashes for two seconds. Then, the history information will be erased, and the averaging will continue from where it was before the reset. DISTANCE TO EMPTY (DTE) NOTE: Significant changes in driving style or vehicle loading will greatly affect the actual drivable distance of the vehicle, regardless of the DTE displayed value. Shows the estimated distance that can be travelled with the fuel remaining in the tank. This estimated distance is determined by a weighted average of the instantaneous and average fuel economy, according to the current fuel tank level. This is not resettable. When the DTE value is less than 30 miles (48 kilometers) estimated driving distance, the DTE display will change to a text display of "LOW FUEL". This display will continue until the vehicle runs out of fuel. Adding a significant amount of fuel to the vehicle will turn off the "LOW FUEL" text and a new DTE value will be displayed, based on the current values in the DTE calculation and the current fuel tank level. ELAPSED TIME Shows the total elapsed time of travel since the last reset when the ignition switch is in the ACC position. Elapsed time will increment when the ignition switch is in the ON or START position. HANDS FREE TELEPHONE MODE - IF EQUIPPED Provides the following information and features for the optional hands-free communications system: - Phone status: idle, voice mail, roaming, battery strength and signal strength in increments of 20 percent - Call status: Incoming call, connecting, connected, air time in minutes and seconds, call ended, busy, call failed, roaming and no phone connection - Caller ID phone number display PERSONAL SETTINGS MODE (CUSTOMER PROGRAMMABLE FEATURES) Allows the driver to set and recall features when the transmission is in Park by pressing and releasing the STEP button until Personal Settings is displayed in the EVIC. The following personal settings can be set and recalled: - Language: English, Spanish and French (domestic markets) German and Italian (export markets) - Lock doors automatically at 15 mph (24 km/h), On or Off - Unlock door automatically on exit, On or Off - Remote Keyless Entry unlock driver door on first press or unlock all doors on first press - Sound horn with Remote Keyless Entry Lock, On or Off - Turn headlamps on with Remote Keyless Entry Lock, On or Off - Delay turning headlamps off for 0, 30, 60 or 90 seconds - Key-Off Power Delay (delay power off to accessories until exit off, 45-seconds maximum, 5-minute maximum, 10-minute maximum) - Illuminated Approach - Turn headlamps on with Remote Keyless Entry Unlock, Off or 30, 60 or 90 seconds - Display units in English or Metric - Compass Variance Setting 1 through 15 - Calibrate Compass Yes/No Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Page 8216 Driver/Vehicle Information Display: Testing and Inspection ELECTRONIC VEHICLE INFORMATION CENTER CAUTION: Do not place any external magnets, such as magnetic roof mount antennas, in the vicinity of the compass. Do not place any electronic devices (cell phones, laptop computers, PDAs, portable DVD players, etc), on or near the instrument panel as the Remote Compass Module (RCM) performance may be effected. Do not use magnetic tools when servicing the RCM. The Electronic Vehicle Information Center (EVIC) data is obtained from several components on the Controller Area Network (CAN) and Local Interface Network (LIN) Data Bus circuits. The EVIC will not function properly if the bus messages from any of these components is not received. If no EVIC data is displayed or the display indicates dashes "- -", check the CAN Data Bus circuit communications, the Instrument Cluster functions, the Remote Compass Module (RCM) and the Totally Integrated Power Module (TIPM). The use of a scan tool and the proper diagnostic procedures information are recommended for further testing of the EVIC, the RCM, the CAN Data Bus and Local Interface Network (LIN) Data Bus circuits. Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Adjustments > Compass Calibration Driver/Vehicle Information Display: Adjustments Compass Calibration COMPASS CALIBRATION CAUTION: Do not place any external magnets, such as magnetic roof mount antennas, in the vicinity of the compass. Do not place any electronic devices (cell phones, laptop computers, PDA's, portable DVD players, etc), on or near the instrument panel as the Remote Compass Module (RCM) performance may be effected. Do not use magnetic tools when servicing the RCM. The electronic compass unit features a continuous self-calibrating feature. This feature automatically updates the compass calibration as the vehicle is driven. This allows the compass unit to compensate for small changes in the residual magnetism that the vehicle may acquire during normal use. If the compass readings appear to be erratic or the Electronic Vehicle Information Center (EVIC) displays "CAL", perform the following calibration procedure. Also, any time a new RCM is installed, it must be calibrated using this procedure. Calibrate the compass manually as follows: NOTE: Do not attempt to calibrate the compass near large metal objects such as other vehicles, large buildings, or bridges; or, near overhead or underground power lines. 1. Start the engine but leave the vehicle in "PARK". 2. Continue to depress and release the STEP button (28) until the "Personal Settings" menu is displayed. 3. Once in the "Personal Settings" menu depress and release the STEP button (28) several times until "Calibrate Compass (Yes)" is displayed. 4. A long (longer than two seconds) STEP button press will place the compass in calibration mode. The "Cal" indicator will change from flashing to on continuously in the EVIC display (29) to indicate that the compass is now in the calibration mode and that the vehicle can now be driven to calibrate. (A short STEP button press from the "Calibrate Compass (Yes)" screen will exit the EVIC Customer Programmable features, and return it to its normal operating mode). 5. To complete the compass calibration, drive the vehicle in one or more complete 360 degree circles under 5 mph (8 km/h) in an area free of large metal objects such as other vehicles, large buildings, or bridges; or, near overhead or underground power lines, until the "CAL" indicator turns off. The compass will now function normally. NOTE: If the compass display indicates an inaccurate compass heading or the display is locked up, the RCM may be inoperative or the vehicle may need to be demagnetized. Perform the Compass Demagnetizing Procedure prior to performing any system diagnosis. NOTE: If the compass display indicates dashes "- -" the RCM may be inoperative or the vehicle may need to be demagnetized. Perform the Compass Demagnetizing Procedure prior to performing any system diagnosis. NOTE: If the "CAL" message remains in the display or if the compass heading is inaccurate following the calibration procedure and there are no internal compass faults, either there is excessive magnetism near the compass, or the unit is inoperative. Repeat the calibration procedure at least one more time prior to performing any system diagnosis. NOTE: If the wrong direction is still indicated in the compass display, the area selected for calibration may be too close to a strong magnetic field. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Adjustments > Compass Calibration > Page 8219 Repeat the calibration procedure in another location. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Adjustments > Compass Calibration > Page 8220 Driver/Vehicle Information Display: Adjustments Compass Variance Adjustment COMPASS VARIANCE ADJUSTMENT Compass variance, also known as magnetic declination, is the difference in angle between magnetic north and geographic north. In some geographic locations, the difference between magnetic and geographic north is great enough to cause the compass to give inaccurate readings. To optimize compass accuracy, the compass variance should be properly set according to the compass variance map zone for the region that the vehicle is in. To set the compass variance: 1. Using the Variance Settings map, find your geographic location and note the zone number. 2. Turn the ignition switch to the On position. 3. Continue to depress and release the STEP button (28) until the "Personal Settings" menu is displayed. 4. Once in the "Personal Settings" menu depress and release the STEP button (28) several times until "Compass Variance" is displayed. The "Compass Variance" message and the current variance zone number will be displayed. The default variance zone is 8. NOTE: During programming, the Zone value will wrap around from Zone 15 to Zone 1. 5. To change the zone, press and hold (longer than two seconds) the STEP button to increment the variance one step. Repeat as necessary, with individual long (longer than two seconds) STEP button presses for each increment, until the desired variance is achieved. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Adjustments > Compass Calibration > Page 8221 6. To exit the Variance Programming, press the STEP button with a short (less than one second) button press. 7. Confirm that the correct directions are now indicated by the compass. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Adjustments > Page 8222 Driver/Vehicle Information Display: Service and Repair COMPASS DEMAGNETIZING A degaussing tool (Special Tool 6029) is used to demagnetize, or degauss, the roof panel above the overhead console. Equivalent units must be rated as continuous duty for 110/115 volts and 60 Hz. They must also have a field strength of over 350 gauss at 7 millimeters (0.25 inch) beyond the tip of the probe. To demagnetize the roof panel proceed as follows: 1. Be certain that the ignition switch is in the Off position, before you begin the demagnetizing procedure. 2. Place a piece of paper approximately 22 by 28 centimeters (8.5 by 11 inches), oriented on the vehicle lengthwise from front to rear, on the center line of the roof at the windshield header. The purpose of the paper is to protect the roof panel from scratches, and to define the area to be demagnetized. 3. Connect the degaussing tool to an electrical outlet, while keeping the tool at least 61 centimeters (2 feet) away from the compass unit. 4. Slowly approach the center line of the roof panel at the windshield header, with the degaussing tool connected. 5. Contact the roof panel with the plastic coated tip of the degaussing tool. Be sure that the template is in place to avoid scratching the roof panel. Using a slow, back-and-forth sweeping motion, and allowing 13 millimeters (0.50 inch) between passes, move the tool at least 11 centimeters (4 inches) to each side of the roof center line, and 28 centimeters (11 inches) back from the windshield header. 6. With the degaussing tool still energized, slowly back it away from the roof panel. When the tip of the tool is at least 61 centimeters (2 feet) from the roof panel, disconnect the tool. 7. Calibrate the compass and adjust the compass variance. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Adjustments > Page 8223 Driver/Vehicle Information Display: Tools and Equipment ELECTRONIC VEHICLE INFORMATION CENTER DEGAUSSING TOOL 6029 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Locations Garage Door Opener Transmitter: Locations Component ID: 166 Component : MODULE-UGDO Connector: Name : MODULE-UGDO Color : BLACK # of pins : 2 A FUSED B(+) (I.O.D.) A417 20RD/DG B UGDO ENABLE CONTROL CIRCUIT G38 20GY/BK Component Location - 43 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Locations > Page 8227 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Locations > Page 8228 Garage Door Opener Transmitter: Diagrams Component ID: 166 Component : MODULE-UGDO Connector: Name : MODULE-UGDO Color : BLACK # of pins : 2 A FUSED B(+) (I.O.D.) A417 20RD/DG B UGDO ENABLE CONTROL CIRCUIT G38 20GY/BK Component Location - 43 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Locations > Page 8229 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Description and Operation > Description Garage Door Opener Transmitter: Description and Operation Description DESCRIPTION Some vehicles are equipped with a Universal Transmitter transceiver (4). The universal transmitter transceiver (4) is located in the headliner (5) just to the rear of the courtesy/reading lamps (1). The only visible component of the universal transmitter are the three transmitter push buttons. The three universal transmitter push buttons are identified with raised buttons and contain a transmit indicator that lights during operation and programming functions. Each of the three universal transmitter push buttons controls an independent radio transmitter channel. Each of these three channels can be trained to transmit a different radio frequency signal for the remote operation of garage door openers, motorized gate openers, home or office lighting, security systems or just about any other device that can be equipped with a radio receiver in the 280 to 435 MegaHertz (MHz) frequency range for remote operation. The universal transmitter is capable of operating systems using either rolling code or non-rolling code technology. The system will not transmit operating signals if the Vehicle Theft Security System is armed. The universal transmitter cannot be repaired, and if inoperative or damaged, the complete module assembly must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Description and Operation > Description > Page 8232 Garage Door Opener Transmitter: Description and Operation Operation OPERATION The HomeLink(R) transceiver operates on a non-switched source of battery current so the unit will remain functional, regardless of the ignition switch position. For more information on the features, programming procedures and operation of the HomeLink(R) transceiver, see the owner's manual in the vehicle glove box. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Component Tests and General Diagnostics Garage Door Opener Transmitter: Component Tests and General Diagnostics UNIVERSAL TRANSMITTER If the Universal Transmitter is inoperative, retrain the universal transmitter with a known good transmitter, insuring the transmitter battery is OK. Test the universal transmitter operation again. If the unit is still inoperative, test the universal transmitter with Radio Frequency Detector special tool as described below: 1. Turn the Radio Frequency (RF) Detector ON (3). A "chirp" will sound and the green power Light Emitting Diode (LED) will light (2). If the green LED does not light, replace the battery (4). 2. Hold the RF detector within 2.5 cm (1 inch) of the TRAINED universal transmitter and press any of the transmitters buttons. 3. The red signal detection LEDs (1) will light and the tool will beep if a radio signal is detected. Repeat this test for all three transmitter buttons. If the tool does not detect a radio signal for any of the three buttons, replace the inoperative universal transmitter assembly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 8235 Garage Door Opener Transmitter: Programming and Relearning Erasing Transmitter Codes ERASING TRANSMITTER CODES NOTE: Individual channels cannot be erased. Erasing the transmitter codes will erase ALL programmed codes. To erase programming from the three buttons (individual buttons cannot be erased but can be "reprogrammed"), follow the step noted: - Press and hold the two outer HomeLink(R) buttons until the indicator light begins to flash after 20 seconds. Release both buttons. Do not hold for longer that 30 seconds. HomeLink(R) is now in the train (or learning) mode and can be programmed at any time beginning with "Programming". Programming Homelink(R) Transceiver Codes PROGRAMMING HOMELINK(R) TRANSCEIVER CODES Programming Common HomeLink(R) Transmitter Codes WARNING: Vehicle exhaust contains carbon monoxide, a dangerous gas. Do not run the vehicle's exhaust while training the transceiver. Exhaust gas can cause serious injury or death. WARNING: Your motorized door or gate may open and close while you are training the HomeLink(R) Transceiver if the vehicle is in range of the motorized device. Do not train the HomeLink(R) transceiver if people or pets are in the path of the door or gate. A moving door or gate can cause serious injury or death to people and pets or damage to objects. NOTE: When programming a garage door opener, it is advised to park outside the garage. It is also recommended that a new battery be placed in the hand-held transmitter of the device being programmed to HomeLink(R) for quicker training and accurate transmission of the radio-frequency signal. NOTE: If programing the HomeLink(R) transceiver is unsuccessful using the following procedure, refer to the Owner's Manual for the current customer assistance phone number. - Press and hold the two outer HomeLink(R) buttons, and release only when the indicator light begins to flash ( after 20 seconds ). Do not hold the buttons for longer than 30 seconds and do not repeat step one to program a second and/or third hand-held transmitter to the remaining two HomeLink(R) buttons. - Position the end of your hand-held transmitter 3-8 cm (1-3 inches) away from the HomeLink(R) buttons while keeping the indicator light in view. - Simultaneously press and hold both the HomeLink(R) buttons that you want to train and the hand-held transmitter button. Do not release the buttons until step 4 has been completed. NOTE: Some gate operators and garage door openers may require you to replace this Programming Step 3 with procedures noted in the "Gate Operator/Canadian Programming" section. - The HomeLink(R) indicator light will flash slowly and then rapidly after HomeLink(R) successfully receives the frequency signal from the hand-held transmitter. Release both buttons after the indicator light changes from the slow to the rapid flash. - Press and hold the just trained HomeLink(R) button and observe the indicator light. If the indicator light stays on constantly, programming is complete and your device should activate when the HomeLink(R) button is pressed and released. NOTE: To program the remaining two HomeLink(R) buttons, begin with "Programming" step 2. Do not repeat step 1. If the indicator light blinks rapidly for two seconds and then turns to a constant light, continue with "Programming" steps 6-8 to complete the programming of a rolling code equipped device (most commonly a garage door opener). - At the garage door opener receiver (motor-head unit) in the garage, locate the "learn" or "smart" button. This can usually be found where the hanging antenna wire is attached to the motor-head unit. - Firmly press and release the "learn" or "smart" button. (The name and color of the button may vary by manufacturer.) NOTE: There are 30 seconds in which to initiate step 8. - Return to the vehicle and firmly press, hold for two seconds and release the programmed HomeLink(R) button. Repeat the "press/hold/release" sequence a second time, and, depending on the brand of the garage door opener (or other rolling code equipped device), repeat this sequence a third time to complete the programming. HomeLink(R) should now activate your rolling code equipped device. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 8236 NOTE: To program the remaining two HomeLink(R) buttons, begin with "Programming" step 2. Do not repeat step 1. Canadian Programming/Gate Programming Canadian radio-frequency laws require transmitter signals to "time-out" (or quit) after several seconds of transmission which may not be long enough for HomeLink(R) to pick up the signal during programming. Similar to this Canadian law, some U.S. gate operators are designed to "time-out" in the same manner. If you live in Canada or you are having difficulties programming a gate operator by using the "Programming" procedures (regardless of where you live), replace "Programming HomeLink(R)" step 3 with the following: NOTE: When programming a garage door opener or gate operator, it is advised to unplug the device or move the vehicle out of range during the "cycling" process to prevent possible overheating. - 3. Continue to press and hold the HomeLink(R) button while you press and release every two seconds ("cycle") your hand-held transmitter until the frequency signal has successfully been accepted by HomeLink(R). (The indicator light will flash slowly and then rapidly.) Proceed with "Programming" step 4 to complete. Reprogramming Homelink(R) Transmitter Codes REPROGRAMMING HOMELINK(R) TRANSMITTER CODES Reprogramming Basic HomeLink(R) Transmitter Codes WARNING: Vehicle exhaust contains carbon monoxide, a dangerous gas. Do not run the vehicle's exhaust while training the HomeLink(R) transceiver. Exhaust gas can cause serious injury or death. WARNING: Your motorized door or gate may open and close while you are training the HomeLink(R) Transceiver if the vehicle is in range of the motorized device. Do not train the HomeLink(R) transceiver if people or pets are in the path of the door or gate. A moving door or gate can cause serious injury or death to people and pets or damage to objects. NOTE: If programing the HomeLink(R) transceiver is unsuccessful using the following procedure, refer to the Owner's Manual for the current customer assistance phone number. To program a device to the HomeLink(R) transceiver using a button previously trained, follow these steps: - Press and hold the desired HomeLink(R) transceiver button. DO NOT release the button. The indicator light will begin to flash after 20 seconds. Without releasing the HomeLink(R) transceiver button, proceed to step 2. - Position the end of your hand-held transmitter 3-8 cm (1-3 inches) away from the HomeLink(R) transceiver button while keeping the indicator light in view. - Simultaneously press and hold both the HomeLink(R) transceiver button that you want to train and the hand-held transmitter buttons. Do not release the buttons until step 4 has been completed. NOTE: Some gate operators and garage door openers may require you to replace this Reprogramming Step 3 with procedures noted in the "Gate Operator/Canadian Programming" section. - The HomeLink(R) transceiver indicator light will flash slowly and then rapidly after it successfully receives the frequency signal from the hand-held transmitter. Release both buttons after the indicator light changes from the slow to the rapid flash. - Press and hold the just trained HomeLink(R) transceiver button and observe the indicator light. If the indicator light stays on constantly, reprogramming is complete and your device should activate when the button is pressed and released. NOTE: If the indicator light blinks rapidly for two seconds and then turns to a constant light, continue with "Reprogramming" steps 6-8 to complete the programming of a rolling code equipped device (most commonly a garage door opener). - At the garage door opener receiver (motor-head unit) in the garage, locate the "learn" or "smart" button. This can usually be found where the hanging antenna wire is attached to the motor-head unit. - Firmly press and release the "learn" or "smart" button. (The name and color of the button may vary by manufacturer.) NOTE: There are 30 seconds in which to initiate step 8. - Return to the vehicle and firmly press, hold for two seconds and release the reprogrammed HomeLink(R) transceiver button. Repeat the "press/hold/release" sequence a second time, and, depending on the brand of the garage door opener (or other rolling code equipped device), repeat this sequence a third time to complete the reprogramming. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 8237 The HomeLink(R) transceiver should now activate your rolling code equipped device. Canadian Programming/Gate Programming Canadian radio-frequency laws require transmitter signals to "time-out" (or quit) after several seconds of transmission which may not be long enough for HomeLink(R) to pick up the signal during programming. Similar to this Canadian law, some U.S. gate operators are designed to "time-out" in the same manner. If you live in Canada or you are having difficulties programming a gate operator by using the "Programming" procedures (regardless of where you live), replace "Programming HomeLink(R)" step 3 with the following: NOTE: When programming a garage door opener or gate operator, it is advised to unplug the device or move the vehicle out of range during the "cycling" process to prevent possible overheating. - 3. Continue to press and hold the HomeLink(R) button while you press and release every two seconds ("cycle") your hand-held transmitter until the frequency signal has successfully been accepted by HomeLink(R). (The indicator light will flash slowly and then rapidly.) Proceed with "Programming" step 4 to complete. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Removal Garage Door Opener Transmitter: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the courtesy/reading lamp lens (5). Insert a suitable flat bladed tool into the slot (6) in the courtesy/reading lamp assembly (2). Pivot the lens down and to the left to release the holding tab (4). Remove the lamp assembly from the headliner (3). 3. Using an appropriate flat bladed tool, remove the universal transmitter button trim bezel (4). 4. Working through the courtesy/reading lamp hole in the headliner, pull the universal transmitter module (1) forward and down through the Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Removal > Page 8240 headliner (2). 5. Disconnect the electrical connector. 6. Remove the universal transmitter module from the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Removal > Page 8241 Garage Door Opener Transmitter: Service and Repair Installation INSTALLATION 1. Position the universal transmitter module (1) into the vehicle. 2. Connect the electrical connector (4). 3. Working through the courtesy/reading lamp hole in the headliner (2), insert the universal transmitter module up into place over the cut out for the button bezel (3). 4. Position the universal transmitter module (2) so that the mounting tabs (4) on the button bezel (5) are aligned with the module slots. 5. Holding the module in place push the universal transmitter button bezel through the headliner until the mounting tabs are securely engaged with the module. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Removal > Page 8242 6. Position the courtesy/reading lamp assembly (2) into the headliner (3). 7. Insert the mounting tab (4) on the lamp lens (5) into the right side of the lamp assembly and pivot the lens up until it snaps securely in place. 8. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Description and Operation Integrated Accessory Switch Assembly: Description and Operation DESCRIPTION There is an Accessory Switch Bank Module (ASBM) located in the instrument panel center stack just below the heater a/c control. Included in this switch bank are: - Electronic Stability Program (ESP)/Traction Control Switch (TCS) Off (if equipped) - Hazard Switch (all models) - Heated Seat Switch (if equipped) - Passenger Airbag Disabled Lamp (PADL) Indicator (if equipped with OCS) The BUX version of the ASBM will vary from the domestic a bit. Following are the various BUX switches: - Anti-Skid Control (ASC) (if equipped) - This is the same as the ESP/TCS off switch in the domestic version. - Hazard Switch (all models) - Heated Seat Switch (if equipped) - Headlamp Leveling Switch (if equipped) Each individual switch is not available for service replacement. If one or more switches are inoperative, the entire ASBM must be replaced. To diagnose the ASBM switches, use a scan tool and the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Service and Repair > Removal Integrated Accessory Switch Assembly: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel center bezel. 3. Remove the screws to the Accessory Switch Bank Module (ASBM) (4). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Service and Repair > Removal > Page 8248 Integrated Accessory Switch Assembly: Service and Repair Installation INSTALLATION 1. Position the Accessory Switch Bank Module (ASBM) (4) in the center bezel. 2. Install the screws to the ASBM. 3. Install the instrument panel center bezel. 4. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Diagrams Navigation Module: Diagrams Component ID: 164 Component : MODULE-TRAFFIC INFORMATION RECEIVER Connector: Name : MODULE-TRAFFIC INFORMATION RECEIVER Color : # of pins : 12 Pin Description Circuit 1-2 CAN B BUS (+) D55 20WT/OR 3-4-5-6 FUSED B(+) (I.O.D.) A413 20RD/LB 7 GROUND Z909 20BK 8 CAN B BUS (-) D54 20WT/PK 9-10 - 11 - 12 - - Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Locations Amplifier: Locations Component ID: 9 Component : AMPLIFIER-RADIO Connector: Name : AMPLIFIER-RADIO C1 Color : WHITE # of pins : 20 Pin Description Circuit 1 LEFT INSTRUMENT PANEL SPEAKER (+) X209 18GY/TN 2 RIGHT INSTRUMENT PANEL SPEAKER (+) X208 18GY/DG 3-4 FUSED B(+) (I.O.D.) A419 18RD/DG 4 FUSED B(+) (I.O.D.) A419 18RD/YL 5-6 CAN B BUS (+) D55 20WT/OR 7 LEFT REAR SPEAKER (+) X51 18DG/DB 8 RIGHT REAR SPEAKER (+) X52 18GY/DB 9 GROUND Z960 16BK/LB 10 LEFT INSTRUMENT PANEL SPEAKER (-) X299 18GY/BR 11 RIGHT INSTRUMENT PANEL SPEAKER (-) X298 18GY/LG 12 - 13 FUSED B(+) (I.O.D.) A420 18WT/RD 14 - 15 - 16 - 17 CAN B BUS (-) D54 20WT/PK 18 LEFT REAR SPEAKER (-) X57 18DG/BR 19 RIGHT REAR SPEAKER (-) X58 18GY/OR 20 GROUND Z960 16BK/LB Component Location - 63 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Locations > Page 8257 Connector: Name : AMPLIFIER-RADIO C2 Color : WHITE # of pins : 14 Pin Description Circuit 1 AMPLIFIED LEFT FRONT DOOR SPEAKER (+) X153 18DG/VT 2 AMPLIFIED RIGHT FRONT DOOR SPEAKER (-) X154 18GY/YL 3 AMPLIFIED LEFT REAR SPEAKER (+) X205 18GY/LG 4 AMPLIFIED RIGHT REAR SPEAKER (+) X206 18DG/LG 5 AMPLIFIED LIFTGATE SPEAKER 1 (+) X214 18DG/DB Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Locations > Page 8258 6 AMPLIFIED LIFTGATE SPEAKER 2 (+) X212 18GY/DB 7 AMPLIFIED LEFT FRONT DOOR SPEAKER (-)X155 18DG/BK 8 AMPLIFIED RIGHT FRONT DOOR SPEAKER (+) X156 18GY/LB 9 AMPLIFIED LEFT REAR SPEAKER (-) X295 18GY/DG 10 - 11 - 12 AMPLIFIED RIGHT REAR SPEAKER (-) X296 18DG/GY 12 AMPLIFIED RIGHT REAR SPEAKER (-) X296 18DG/LB 13 AMPLIFIED LIFTGATE SPEAKER 1 (-) X284 18DG/TN 14 AMPLIFIED LIFTGATE SPEAKER 2 (-) X282 18GY/TN Component Location - 63 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Locations > Page 8259 Amplifier: Diagrams Component ID: 9 Component : AMPLIFIER-RADIO Connector: Name : AMPLIFIER-RADIO C1 Color : WHITE # of pins : 20 Pin Description Circuit 1 LEFT INSTRUMENT PANEL SPEAKER (+) X209 18GY/TN 2 RIGHT INSTRUMENT PANEL SPEAKER (+) X208 18GY/DG 3-4 FUSED B(+) (I.O.D.) A419 18RD/DG 4 FUSED B(+) (I.O.D.) A419 18RD/YL 5-6 CAN B BUS (+) D55 20WT/OR 7 LEFT REAR SPEAKER (+) X51 18DG/DB 8 RIGHT REAR SPEAKER (+) X52 18GY/DB 9 GROUND Z960 16BK/LB 10 LEFT INSTRUMENT PANEL SPEAKER (-) X299 18GY/BR 11 RIGHT INSTRUMENT PANEL SPEAKER (-) X298 18GY/LG 12 - 13 FUSED B(+) (I.O.D.) A420 18WT/RD 14 - 15 - 16 - 17 CAN B BUS (-) D54 20WT/PK 18 LEFT REAR SPEAKER (-) X57 18DG/BR 19 RIGHT REAR SPEAKER (-) X58 18GY/OR 20 GROUND Z960 16BK/LB Component Location - 63 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Locations > Page 8260 Connector: Name : AMPLIFIER-RADIO C2 Color : WHITE # of pins : 14 Pin Description Circuit 1 AMPLIFIED LEFT FRONT DOOR SPEAKER (+) X153 18DG/VT 2 AMPLIFIED RIGHT FRONT DOOR SPEAKER (-) X154 18GY/YL 3 AMPLIFIED LEFT REAR SPEAKER (+) X205 18GY/LG 4 AMPLIFIED RIGHT REAR SPEAKER (+) X206 18DG/LG 5 AMPLIFIED LIFTGATE SPEAKER 1 (+) X214 18DG/DB Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Locations > Page 8261 6 AMPLIFIED LIFTGATE SPEAKER 2 (+) X212 18GY/DB 7 AMPLIFIED LEFT FRONT DOOR SPEAKER (-)X155 18DG/BK 8 AMPLIFIED RIGHT FRONT DOOR SPEAKER (+) X156 18GY/LB 9 AMPLIFIED LEFT REAR SPEAKER (-) X295 18GY/DG 10 - 11 - 12 AMPLIFIED RIGHT REAR SPEAKER (-) X296 18DG/GY 12 AMPLIFIED RIGHT REAR SPEAKER (-) X296 18DG/LB 13 AMPLIFIED LIFTGATE SPEAKER 1 (-) X284 18DG/TN 14 AMPLIFIED LIFTGATE SPEAKER 2 (-) X282 18GY/TN Component Location - 63 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Description and Operation > Description Amplifier: Description and Operation Description DESCRIPTION The optional premium speaker system includes a separate audio power amplifier. The amplifier is located on the floor behind the spare tire in the trunk. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Description and Operation > Description > Page 8264 Amplifier: Description and Operation Operation OPERATION The power amplifier electronically increases the frequency response of the normal audio signal output from the radio amplifier in order to improve the acoustic performance of the speakers. On vehicles equipped with an amplifier, the amplifier section of the radio becomes a pre-amplifier. The amplifier receives audio signal inputs for speaker channels from the radio, then sends amplified audio outputs with dedicated feed and return circuits to the individual speakers. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Service and Repair > Removal Amplifier: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the retaining fasteners. 3. Disconnect the wire harness connector. 4. Remove the amplifier (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Service and Repair > Removal > Page 8267 Amplifier: Service and Repair Installation INSTALLATION 1. Install amplifier (1). 2. Install the mounting fasteners. 3. Connect wire harness connector to amplifier. 4. Connect battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio Receiver > Component Information > Description and Operation > Description Radio Receiver: Description and Operation Description DESCRIPTION The satellite receiver module is located behind the spare tire. It is mounted to a bracket which is fastened to the trunk floor sheet metal. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio Receiver > Component Information > Description and Operation > Description > Page 8273 Radio Receiver: Description and Operation Operation OPERATION The satellite receiver module receives signals from the roof mounted antenna and processes this information before it is sent to the radio. The module operates on both battery and accessory feed circuits and will operate with the ignition key in the RUN or ACCESSORY position only. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio Receiver > Component Information > Service and Repair > Removal Radio Receiver: Service and Repair Removal REMOVAL NOTE: If the owner's satellite service was active before the satellite receiver module was replaced the new satellite receiver module will have to be activated. The existing satellite receiver module will have to be deactivated before the replacement satellite receiver module can be activated. To activate Sirius satellite radio service, call Sirius at their toll-free number. Please have the following information available when activating a system: - Electronic Serial Number / Sirius Identification Number (ESN/SID) of the unit to be replaced - ESN/SID of the replacement receiver - Vehicle Owner's name and address - VIN The ESN/SID number can be obtained through the radio display by following the steps in the satellite radio owners manual. The vehicle must be outside with the audio system powered on, in the satellite radio mode, to receive the activation signal. 1. Disconnect and isolate the battery negative cable. 2. Remove the left rear quarter trim panel. 3. Remove the mounting bracket fasteners. 4. Disconnect the wire harness connectors. 5. Remove the module from the mounting bracket. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio Receiver > Component Information > Service and Repair > Removal > Page 8276 Radio Receiver: Service and Repair Installation INSTALLATION NOTE: If the owner's satellite service was active before the satellite receiver module was replaced the new satellite receiver module will have to be activated. The existing satellite receiver module will have to be deactivated before the replacement satellite receiver module can be activated. To activate Sirius satellite radio service, call Sirius at their toll-free number. Please have the following information available when activating a system: - Electronic Serial Number / Sirius Identification Number (ESN/SID) of the unit to be replaced - ESN/SID of the replacement receiver - Vehicle Owner's name and address - VIN The ESN/SID number can be obtained through the radio display by following the steps in the satellite radio owners manual. The vehicle must be outside with the audio system powered on, in the satellite radio mode, to receive the activation signal. 1. Position the module to the mounting bracket. 2. Connect wire harness connectors. 3. Install mounting bracket and fasteners. 4. Install the left rear quarter trim panel. 5. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Description and Operation > Description Radio/Stereo Noise Filter: Description and Operation Description DESCRIPTION Radio noise suppression devices are factory-installed standard equipment on this vehicle. Radio Frequency Interference (RFI) and ElectroMagnetic Interference (EMI) can be produced by any on-board or external source of electromagnetic energy. These electromagnetic energy sources can radiate electromagnetic signals through the air, or conduct them through the vehicle electrical system. When the audio system converts RFI or EMI to an audible acoustic wave form, it is referred to as radio noise. This undesirable radio noise is generally manifested in the form of "buzzing", "hissing", "popping", "clicking", "crackling", and/or "whirring" sounds. In most cases, RFI and EMI radio noise can be suppressed using a combination of vehicle and component grounding, filtering and shielding techniques. This vehicle is equipped with factory-installed radio noise suppression devices that were designed to minimize exposure to typical sources of RFI and EMI; thereby, minimizing radio noise complaints. Radio noise suppression is accomplished primarily through circuitry or devices that are integral to the radios, audio power amplifiers and other on-board electrical components such as generators, wiper motors, blower motors, and fuel pumps that have been found to be potential sources of RFI or EMI. External radio noise suppression devices that are used on this vehicle to control RFI or EMI, and can be serviced, include the following: Ground straps - This length of braided ground strap has an eyelet terminal connector crimped to each end. They are located in various locations on the vehicle. - Radio Noise Suppression Capacitor - This component is attached near the exhaust manifold. - Resistor-type spark plugs - This type of spark plug has an internal resistor connected in series between the spark plug terminal and the center electrode to help reduce the production of electromagnetic radiation that can result in radio noise. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Description and Operation > Description > Page 8281 Radio/Stereo Noise Filter: Description and Operation Operation OPERATION There are two common strategies that can be used to suppress Radio Frequency Interference (RFI) and ElectroMagnetic Interference (EMI) radio noise. The first suppression strategy involves preventing the production of RFI and EMI electromagnetic signals at their sources. The second suppression strategy involves preventing the reception of RFI and EMI electromagnetic signals by the audio system components. The use of braided ground straps in key locations is part of the RFI and EMI prevention strategy. These ground straps ensure adequate ground paths, particularly for high current components such as many of those found in the starting, charging, ignition, engine control and transmission control systems. An insufficient ground path for any of these high current components may result in radio noise caused by induced voltages created as the high current seeks alternative ground paths through components or circuits intended for use by, or in close proximity to the audio system components or circuits. Preventing the reception of RFI and EMI is accomplished by ensuring that the audio system components are correctly installed in the vehicle. Loose, corroded or improperly soldered wire harness connections, improperly routed wiring and inadequate audio system component grounding can all contribute to the reception of RFI and EMI. A properly grounded antenna body and radio chassis, as well as a shielded antenna coaxial cable with clean and tight connections will each help reduce the potential for reception of RFI and EMI. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service and Repair > Removal Radio/Stereo Noise Filter: Service and Repair Removal REMOVAL ENGINE GROUND STRAP 1. Disconnect and isolate the battery negative cable. 2. For the 1.6L Engine, remove bolt from engine cylinder head. 3. For the 2.0/2.4L Engine, remove bolt from engine cylinder head. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service and Repair > Removal > Page 8284 4. For the 2.2L Engine, remove bolt from engine cylinder head. 5. Remove bolt from strut tower and remove strap. HOOD HINGE GROUND STRAP 1. Disconnect and isolate the battery negative cable. 2. Remove bolt from fender. 3. Remove bolt from hood and remove strap. MUFFLER GROUND STRAP Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service and Repair > Removal > Page 8285 1. Disconnect and isolate the battery negative cable. 2. Remove bolt from rear floor pan. 3. Remove bolt from muffler and remove strap. RADIO NOISE SUPPRESSION CAPACITOR 1. Disconnect and isolate the battery negative cable. 2. Disconnect electrical harness connector from capacitor (1). 3. Remove bolt from capacitor and remove capacitor. STRUT BRACKET TO BODY GROUND STRAP 1. Disconnect and isolate the battery negative cable. 2. Remove bolt from strut. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service and Repair > Removal > Page 8286 3. Remove strap from frame rail. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service and Repair > Removal > Page 8287 Radio/Stereo Noise Filter: Service and Repair Installation INSTALLATION ENGINE GROUND STRAP 1. Install strap and bolt to strut tower. Tighten bolt to 12 Nm (106 in. lbs.). 2. Install strap and bolt to engine cylinder head. Tighten bolt to 28 Nm (21 ft. lbs.). 3. Connect battery negative cable. HOOD HINGE GROUND STRAP 1. Install strap and bolt to fender. Tighten bolt to 4 Nm (35 in. lbs.). 2. Install strap and bolt to hood. Tighten bolt to 4 Nm (35 in. lbs.). 3. Connect battery negative cable. MUFFLER GROUND STRAP Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service and Repair > Removal > Page 8288 1. Install strap and bolt to rear floor pan. Tighten bolt to 8 Nm (71 in. lbs.). 2. Install strap and bolt to muffler. Tighten bolt to 8 Nm (71 in. lbs.). 3. Connect battery negative cable. RADIO NOISE SUPPRESSION CAPACITOR 1. Install capacitor and bolt. 2. Connect electrical harness connector to capacitor. 3. Connect battery negative cable. STRUT BRACKET TO BODY GROUND STRAP 1. Install strap to frame rail. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service and Repair > Removal > Page 8289 CAUTION: Ensure that ground strap does not come in contact with brake hose. Damage to brake hose can result. 2. Install strap and bolt to strut. Tighten bolt to 12 Nm (106 in. lbs.). 3. Connect battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Description Remote Switch: Description and Operation Description DESCRIPTION Two rocker-type switches (if equipped) are mounted on the back (instrument panel side) of the steering wheel spokes. The switch on the left spoke is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right spoke is the volume control switch and has volume up, and volume down functions. The switch on the right spoke also includes a "mode" control that allows the driver to sequentially select AM radio, FM radio, cassette player, CD player or CD changer (if equipped). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Description > Page 8294 Remote Switch: Description and Operation Operation OPERATION These switches are resistor multiplexed units that are hard-wired to the Cab Compartment Node (CCN) through the clockspring. The CCN sends the proper messages on the Controller Area Network (CAN) data bus network to the radio receiver. For diagnosis of the CCN or the CAN data bus, the use of a scan tool and the proper Diagnostic Procedures manual are recommended. For more information on the operation of the remote radio switch controls, refer to the owner's manual in the vehicle glove box. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Page 8295 Remote Switch: Testing and Inspection REMOTE SWITCHES WARNING: On vehicles equipped with airbags, refer to electrical, restraints before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. Any diagnosis of the Audio system should begin with the use of the scan tool. For information on the use of the scan tool, refer to the appropriate Diagnostic Manual. For complete circuit diagrams, refer to the appropriate wiring information. 1. Disconnect and isolate the battery negative cable. 2. Remove the remote radio switch(es) from the steering wheel. 3. Use an ohmmeter to check the switch resistance as shown in the Remote Radio Switch Test table NOTE: The right remote radio switch back is white in color. The left switch back is black in color. The right/left remote radio switch orientation is with the steering wheel installed, and driver in driver's seat. 4. If the switch resistance checks OK, go to STEP 5. If not OK, replace the faulty switch. 5. Check for continuity between the ground circuit cavity of the switch wire harness connector and a good ground. There should be continuity. If OK, go to STEP 6. If not OK, repair the open circuit as required. 6. Unplug the connector from the Cab Compartment Node (CCN). Check for continuity between the radio control circuit cavity of the remote radio switch wire harness connector and a good ground. There should be no continuity. If OK, go to STEP 7. If not OK, repair the short circuit as required. 7. Check for continuity between the radio control circuit cavities of the remote radio switch wire harness connector and the CCN wire harness connector. There should be continuity. If OK, refer to the proper Diagnostic Procedures manual to test the CCN and the CAN data bus. If not OK, repair the open circuit as required. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Service and Repair > Removal Remote Switch: Service and Repair Removal REMOVAL WARNING: On vehicles equipped with airbags, refer to electrical, restraints before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. 1. Disconnect and isolate the battery negative cable. 2. Remove the driver side airbag. 3. Remove the steering wheel. 4. Unplug the wire harness connector from the remote radio switch. 5. Remove steering wheel rear cover. 6. Remove the remote radio switch from the steering wheel by depressing tabs on each side of each switch. NOTE: The right remote radio switch back is white in color. The left switch back is black in color. The right/left remote radio switch orientation is with the steering wheel installed, and driver in driver's seat. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Service and Repair > Removal > Page 8298 Remote Switch: Service and Repair Installation INSTALLATION WARNING: On vehicles equipped with airbags, refer to electrical, restraints before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. 1. Install remote radio switch to the steering wheel. 2. Install steering wheel rear cover. 3. Connect the wire harness to the remote radio switch. 4. Install the steering wheel. 5. Install the driver side airbag. 6. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Locations > Switch-Remote Radio-Left Remote Control: Locations Switch-Remote Radio-Left Component ID: 353 Component : SWITCH-REMOTE RADIO-LEFT Connector: Name : SWITCH-REMOTE RADIO-LEFT Color : BLACK # of pins : 2 Pin Description Circuit 1 RADIO CONTROL MUX X20 20GY 2 RADIO CONTROL RETURN Y13 20BK Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Locations > Switch-Remote Radio-Left > Page 8303 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Locations > Switch-Remote Radio-Left > Page 8304 Remote Control: Locations Switch-Remote Radio-Right Component ID: 354 Component : SWITCH-REMOTE RADIO-RIGHT Connector: Name : SWITCH-REMOTE RADIO-RIGHT Color : BLACK # of pins : 2 Pin Description Circuit 1 RADIO CONTROL MUX X20 20GY 2 RADIO CONTROL RETURN Y13 20BK Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Locations > Switch-Remote Radio-Left > Page 8305 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Diagrams > Switch-Remote Radio-Left Remote Control: Diagrams Switch-Remote Radio-Left Component ID: 353 Component : SWITCH-REMOTE RADIO-LEFT Connector: Name : SWITCH-REMOTE RADIO-LEFT Color : BLACK # of pins : 2 Pin Description Circuit 1 RADIO CONTROL MUX X20 20GY 2 RADIO CONTROL RETURN Y13 20BK Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Diagrams > Switch-Remote Radio-Left > Page 8308 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Diagrams > Switch-Remote Radio-Left > Page 8309 Remote Control: Diagrams Switch-Remote Radio-Right Component ID: 354 Component : SWITCH-REMOTE RADIO-RIGHT Connector: Name : SWITCH-REMOTE RADIO-RIGHT Color : BLACK # of pins : 2 Pin Description Circuit 1 RADIO CONTROL MUX X20 20GY 2 RADIO CONTROL RETURN Y13 20BK Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Diagrams > Switch-Remote Radio-Left > Page 8310 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 08-024-07A > Nov > 07 > Audio System - Distorted Sound From Speakers Speaker: Customer Interest Audio System - Distorted Sound From Speakers NUMBER: 08-024-07 REV. A GROUP: Electrical DATE: November 30, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-024-07, DATED OCTOBER 10, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF A NEW MODEL. SUBJECT: Distorted Sound In Door Speaker, Rear Quarter Speaker Or Rear Shelf Speaker With The Radio On OVERVIEW: This bulletin involves replacing all 6x9 base (non-premium sound system) speakers in the vehicle. MODELS: 2007 - 2008 (LE) 300, Touring (International Markets) 2007 - 2008 (LX) 300, Charger, Magnum 2007 (L2) 300 (China) 2007-2008 (JS) Avenger/Sebring/Sebring Convertible 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber 2007 - 2008 (WK) Grand Cherokee 2007 - 2008 (WH) Grand Cherokee (International Markets) 2007 - 2008 (XK) Commander 2007 - 2008 (XH) Commander (International markets) 2007 - 2008 (DR) Ram truck 2007 - 2008 (DH/D1/DC) Ram Truck (2500 & 3500) 2008 (RT) Town & Country/Grand Caravan/Grand Voyager (U.S. and International Markets) **2007 (RS/RG) Town & Country/Caravan/Voyager (U.S. and International Markets)** NOTE: This bulletin applies to vehicles built between February 26, 2007 (MDH 0226XX) and September 4, 2007 (MDH 0904XX) and sales code RCB, RCG or RCD SYMPTOM/CONDITION: Some customers may experience a "distorted sound in one or more 6x9 (non-premium sound system) speakers with the radio on. DIAGNOSIS: If the Symptom/Condition is present, perform the Repair Procedure. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 08-024-07A > Nov > 07 > Audio System - Distorted Sound From Speakers > Page 8319 PARTS REQUIRED: REPAIR PROCEDURE: 1. Replace all the 6x9 speakers in the vehicle following the procedures available in DealerCONNECT > TechCONNECT > 8 - Electrical > Radio > Speaker > Removal and Installation. Refer to table below for 6x9 speaker quantities and location details. POLICY: Reimbursable within the provisions of the warranty. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 08-024-07A > Nov > 07 > Audio System - Distorted Sound From Speakers > Page 8320 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 08-024-07A > Nov > 07 > Audio System - Distorted Sound From Speakers Speaker: All Technical Service Bulletins Audio System - Distorted Sound From Speakers NUMBER: 08-024-07 REV. A GROUP: Electrical DATE: November 30, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-024-07, DATED OCTOBER 10, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF A NEW MODEL. SUBJECT: Distorted Sound In Door Speaker, Rear Quarter Speaker Or Rear Shelf Speaker With The Radio On OVERVIEW: This bulletin involves replacing all 6x9 base (non-premium sound system) speakers in the vehicle. MODELS: 2007 - 2008 (LE) 300, Touring (International Markets) 2007 - 2008 (LX) 300, Charger, Magnum 2007 (L2) 300 (China) 2007-2008 (JS) Avenger/Sebring/Sebring Convertible 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber 2007 - 2008 (WK) Grand Cherokee 2007 - 2008 (WH) Grand Cherokee (International Markets) 2007 - 2008 (XK) Commander 2007 - 2008 (XH) Commander (International markets) 2007 - 2008 (DR) Ram truck 2007 - 2008 (DH/D1/DC) Ram Truck (2500 & 3500) 2008 (RT) Town & Country/Grand Caravan/Grand Voyager (U.S. and International Markets) **2007 (RS/RG) Town & Country/Caravan/Voyager (U.S. and International Markets)** NOTE: This bulletin applies to vehicles built between February 26, 2007 (MDH 0226XX) and September 4, 2007 (MDH 0904XX) and sales code RCB, RCG or RCD SYMPTOM/CONDITION: Some customers may experience a "distorted sound in one or more 6x9 (non-premium sound system) speakers with the radio on. DIAGNOSIS: If the Symptom/Condition is present, perform the Repair Procedure. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 08-024-07A > Nov > 07 > Audio System - Distorted Sound From Speakers > Page 8326 PARTS REQUIRED: REPAIR PROCEDURE: 1. Replace all the 6x9 speakers in the vehicle following the procedures available in DealerCONNECT > TechCONNECT > 8 - Electrical > Radio > Speaker > Removal and Installation. Refer to table below for 6x9 speaker quantities and location details. POLICY: Reimbursable within the provisions of the warranty. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 08-024-07A > Nov > 07 > Audio System - Distorted Sound From Speakers > Page 8327 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Left Speaker: Locations Speaker-Instrument Panel-Left Component ID: 329 Component : SPEAKER-INSTRUMENT PANEL-LEFT Connector: Name : SPEAKER-INSTRUMENT PANEL-LEFT Color : WHITE # of pins : 2 Qualifier : (PREMIUM) Pin Description Circuit 1 LEFT INSTRUMENT PANEL SPEAKER (+) X209 18GY/TN 2 LEFT INSTRUMENT PANEL SPEAKER (-) X299 18GY/BR Component Location - 23 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Left > Page 8330 Fig. 23 Component Location - 24 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Left > Page 8331 Component Location - 29 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Left > Page 8332 Fig. 29 Component Location - 31 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Left > Page 8333 Component Location - 33 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Left > Page 8334 Fig. 33 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Left > Page 8335 Speaker: Locations Speaker-Instrument Panel-Right Component ID: 330 Component : SPEAKER-INSTRUMENT PANEL-RIGHT Connector: Name : SPEAKER-INSTRUMENT PANEL-RIGHT Color : WHITE # of pins : 2 Qualifier : (PREMIUM) Pin Description Circuit 1 RIGHT INSTRUMENT PANEL SPEAKER (+) X208 18GY/DG 2 RIGHT INSTRUMENT PANEL SPEAKER (-) X298 18GY/LG Component Location - 23 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Left > Page 8336 Fig. 23 Component Location - 25 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Left > Page 8337 Component Location - 29 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Left > Page 8338 Fig. 29 Component Location - 30 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Left > Page 8339 Component Location - 32 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Left > Page 8340 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Left > Page 8341 Speaker: Locations Speaker-Left Front Door Component ID: 331 Component : SPEAKER-LEFT FRONT DOOR Connector: Name : SPEAKER-LEFT FRONT DOOR Color : WHITE # of pins : 3 Pin Description Circuit 1 LEFT FRONT DOOR SPEAKER (+) X201 18GY/VT Pin Description Circuit 1 AMPLIFIED LEFT FRONT DOOR SPEAKER (+) X201 18GY/VT 2-3 LEFT FRONT DOOR SPEAKER (-) X291 18GY/YL 3 AMPLIFIED LEFT FRONT DOOR SPEAKER (-)X291 18GY/YL Component Location - 53 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Left > Page 8342 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Left > Page 8343 Speaker: Locations Speaker-Left Rear Component ID: 332 Component : SPEAKER-LEFT REAR Connector: Name : SPEAKER-LEFT REAR Color : WHITE # of pins : 3 Pin Description Circuit 1 LEFT REAR SPEAKER (+) X51 18DG/DB Pin Description Circuit 1 AMPLIFIED LEFT REAR SPEAKER (+) X205 18GY/LG 2-3 LEFT REAR SPEAKER (-) X57 18DG/BR 3 AMPLIFIED LEFT REAR SPEAKER (-) X295 18GY/DG Component Location - 55 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Left > Page 8344 Component Location - 56 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Left > Page 8345 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Left > Page 8346 Speaker: Locations Speaker-Instrument Panel-Left Component ID: 329 Component : SPEAKER-INSTRUMENT PANEL-LEFT Connector: Name : SPEAKER-INSTRUMENT PANEL-LEFT Color : WHITE # of pins : 2 Qualifier : (PREMIUM) Pin Description Circuit 1 LEFT INSTRUMENT PANEL SPEAKER (+) X209 18GY/TN 2 LEFT INSTRUMENT PANEL SPEAKER (-) X299 18GY/BR Component Location - 23 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Left > Page 8347 Fig. 23 Component Location - 24 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Left > Page 8348 Component Location - 29 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Left > Page 8349 Fig. 29 Component Location - 31 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Left > Page 8350 Component Location - 33 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Left > Page 8351 Fig. 33 Speaker-Instrument Panel-Right Component ID: 330 Component : SPEAKER-INSTRUMENT PANEL-RIGHT Connector: Name : SPEAKER-INSTRUMENT PANEL-RIGHT Color : WHITE # of pins : 2 Qualifier : (PREMIUM) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Left > Page 8352 Pin Description Circuit 1 RIGHT INSTRUMENT PANEL SPEAKER (+) X208 18GY/DG 2 RIGHT INSTRUMENT PANEL SPEAKER (-) X298 18GY/LG Component Location - 23 Fig. 23 Component Location - 25 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Left > Page 8353 Component Location - 29 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Left > Page 8354 Fig. 29 Component Location - 30 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Left > Page 8355 Component Location - 32 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Left > Page 8356 Speaker-Left Front Door Component ID: 331 Component : SPEAKER-LEFT FRONT DOOR Connector: Name : SPEAKER-LEFT FRONT DOOR Color : WHITE # of pins : 3 Pin Description Circuit Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Left > Page 8357 1 LEFT FRONT DOOR SPEAKER (+) X201 18GY/VT Pin Description Circuit 1 AMPLIFIED LEFT FRONT DOOR SPEAKER (+) X201 18GY/VT 2-3 LEFT FRONT DOOR SPEAKER (-) X291 18GY/YL 3 AMPLIFIED LEFT FRONT DOOR SPEAKER (-)X291 18GY/YL Component Location - 53 Speaker-Left Rear Component ID: 332 Component : SPEAKER-LEFT REAR Connector: Name : SPEAKER-LEFT REAR Color : WHITE # of pins : 3 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Left > Page 8358 Pin Description Circuit 1 LEFT REAR SPEAKER (+) X51 18DG/DB Pin Description Circuit 1 AMPLIFIED LEFT REAR SPEAKER (+) X205 18GY/LG 2-3 LEFT REAR SPEAKER (-) X57 18DG/BR 3 AMPLIFIED LEFT REAR SPEAKER (-) X295 18GY/DG Component Location - 55 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Left > Page 8359 Component Location - 56 Speaker-Liftgate Component ID: 333 Component : SPEAKER-LIFTGATE Connector: Name : SPEAKER-LIFTGATE Color : LT. GRAY # of pins : 4 Qualifier : (EXCEPT BASE) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Left > Page 8360 Pin Description Circuit 1 AMPLIFIED LIFTGATE SPEAKER 1 (+) X214 18DG/DB 2 AMPLIFIED LIFTGATE SPEAKER 1 (-) X284 18DG/TN 3 AMPLIFIED LIFTGATE SPEAKER 2 (+) X212 18GY/DB 4 AMPLIFIED LIFTGATE SPEAKER 2 (-) X282 18GY/TN Component Location - 67 Speaker-Right Front Door Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Left > Page 8361 Component ID: 334 Component : SPEAKER-RIGHT FRONT DOOR Connector: Name : SPEAKER-RIGHT FRONT DOOR Color : WHITE # of pins : 3 Pin Description Circuit 1 RIGHT FRONT DOOR SPEAKER (+) X202 18DG/VT Pin Description Circuit 1 AMPLIFIED RIGHT FRONT DOOR SPEAKER (+) X202 18DG/VT 2-3 RIGHT FRONT DOOR SPEAKER (-) X292 18DG/YL 3 AMPLIFIED RIGHT FRONT DOOR SPEAKER (-) X292 18DG/YL Component Location - 53 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Left > Page 8362 Speaker-Right Rear Component ID: 335 Component : SPEAKER-RIGHT REAR Connector: Name : SPEAKER-RIGHT REAR Color : WHITE # of pins : 3 Pin Description Circuit Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Left > Page 8363 1 RIGHT REAR SPEAKER (+) X52 18GY/DB Pin Description Circuit 1 AMPLIFIED RIGHT REAR SPEAKER (+) X206 18DG/LG 2-3 RIGHT REAR SPEAKER (-) X58 18GY/OR 3 AMPLIFIED RIGHT REAR SPEAKER (-) X296 18DG/GY Component Location - 55 Component Location - 56 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Left > Page 8364 Speaker-Subwoofer Component ID: 336 Component : SPEAKER-SUBWOOFER Connector: Name : SPEAKER-SUBWOOFER Color : WHITE # of pins : 10 Qualifier : (PREMIUM) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Left > Page 8365 Pin Description Circuit 1 POWER ANTENNA SIGNAL X60 20GY/RD 2 GROUND Z960 16BK/LB 3-4-5 FUSED B(+) (I.O.D.) A419 18RD/DG 6-7 AMPLIFIED LEFT REAR SPEAKER (+) X205 18GY/LG 8 AMPLIFIED LEFT REAR SPEAKER (-) X295 18GY/DG 9 AMPLIFIED RIGHT REAR SPEAKER (+) X206 18DG/LG 10 AMPLIFIED RIGHT REAR SPEAKER (-) X296 18DG/LB 10 AMPLIFIED RIGHT REAR SPEAKER (-) X296 18DG/GY Component Location - 63 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Left Speaker: Diagrams Speaker-Instrument Panel-Left Component ID: 329 Component : SPEAKER-INSTRUMENT PANEL-LEFT Connector: Name : SPEAKER-INSTRUMENT PANEL-LEFT Color : WHITE # of pins : 2 Qualifier : (PREMIUM) Pin Description Circuit 1 LEFT INSTRUMENT PANEL SPEAKER (+) X209 18GY/TN 2 LEFT INSTRUMENT PANEL SPEAKER (-) X299 18GY/BR Component Location - 23 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Left > Page 8368 Fig. 23 Component Location - 24 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Left > Page 8369 Component Location - 29 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Left > Page 8370 Fig. 29 Component Location - 31 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Left > Page 8371 Component Location - 33 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Left > Page 8372 Fig. 33 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Left > Page 8373 Speaker: Diagrams Speaker-Instrument Panel-Right Component ID: 330 Component : SPEAKER-INSTRUMENT PANEL-RIGHT Connector: Name : SPEAKER-INSTRUMENT PANEL-RIGHT Color : WHITE # of pins : 2 Qualifier : (PREMIUM) Pin Description Circuit 1 RIGHT INSTRUMENT PANEL SPEAKER (+) X208 18GY/DG 2 RIGHT INSTRUMENT PANEL SPEAKER (-) X298 18GY/LG Component Location - 23 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Left > Page 8374 Fig. 23 Component Location - 25 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Left > Page 8375 Component Location - 29 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Left > Page 8376 Fig. 29 Component Location - 30 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Left > Page 8377 Component Location - 32 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Left > Page 8378 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Left > Page 8379 Speaker: Diagrams Speaker-Left Front Door Component ID: 331 Component : SPEAKER-LEFT FRONT DOOR Connector: Name : SPEAKER-LEFT FRONT DOOR Color : WHITE # of pins : 3 Pin Description Circuit 1 LEFT FRONT DOOR SPEAKER (+) X201 18GY/VT Pin Description Circuit 1 AMPLIFIED LEFT FRONT DOOR SPEAKER (+) X201 18GY/VT 2-3 LEFT FRONT DOOR SPEAKER (-) X291 18GY/YL 3 AMPLIFIED LEFT FRONT DOOR SPEAKER (-)X291 18GY/YL Component Location - 53 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Left > Page 8380 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Left > Page 8381 Speaker: Diagrams Speaker-Left Rear Component ID: 332 Component : SPEAKER-LEFT REAR Connector: Name : SPEAKER-LEFT REAR Color : WHITE # of pins : 3 Pin Description Circuit 1 LEFT REAR SPEAKER (+) X51 18DG/DB Pin Description Circuit 1 AMPLIFIED LEFT REAR SPEAKER (+) X205 18GY/LG 2-3 LEFT REAR SPEAKER (-) X57 18DG/BR 3 AMPLIFIED LEFT REAR SPEAKER (-) X295 18GY/DG Component Location - 55 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Left > Page 8382 Component Location - 56 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Left > Page 8383 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Left > Page 8384 Speaker: Diagrams Speaker-Instrument Panel-Left Component ID: 329 Component : SPEAKER-INSTRUMENT PANEL-LEFT Connector: Name : SPEAKER-INSTRUMENT PANEL-LEFT Color : WHITE # of pins : 2 Qualifier : (PREMIUM) Pin Description Circuit 1 LEFT INSTRUMENT PANEL SPEAKER (+) X209 18GY/TN 2 LEFT INSTRUMENT PANEL SPEAKER (-) X299 18GY/BR Component Location - 23 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Left > Page 8385 Fig. 23 Component Location - 24 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Left > Page 8386 Component Location - 29 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Left > Page 8387 Fig. 29 Component Location - 31 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Left > Page 8388 Component Location - 33 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Left > Page 8389 Fig. 33 Speaker-Instrument Panel-Right Component ID: 330 Component : SPEAKER-INSTRUMENT PANEL-RIGHT Connector: Name : SPEAKER-INSTRUMENT PANEL-RIGHT Color : WHITE # of pins : 2 Qualifier : (PREMIUM) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Left > Page 8390 Pin Description Circuit 1 RIGHT INSTRUMENT PANEL SPEAKER (+) X208 18GY/DG 2 RIGHT INSTRUMENT PANEL SPEAKER (-) X298 18GY/LG Component Location - 23 Fig. 23 Component Location - 25 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Left > Page 8391 Component Location - 29 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Left > Page 8392 Fig. 29 Component Location - 30 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Left > Page 8393 Component Location - 32 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Left > Page 8394 Speaker-Left Front Door Component ID: 331 Component : SPEAKER-LEFT FRONT DOOR Connector: Name : SPEAKER-LEFT FRONT DOOR Color : WHITE # of pins : 3 Pin Description Circuit Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Left > Page 8395 1 LEFT FRONT DOOR SPEAKER (+) X201 18GY/VT Pin Description Circuit 1 AMPLIFIED LEFT FRONT DOOR SPEAKER (+) X201 18GY/VT 2-3 LEFT FRONT DOOR SPEAKER (-) X291 18GY/YL 3 AMPLIFIED LEFT FRONT DOOR SPEAKER (-)X291 18GY/YL Component Location - 53 Speaker-Left Rear Component ID: 332 Component : SPEAKER-LEFT REAR Connector: Name : SPEAKER-LEFT REAR Color : WHITE # of pins : 3 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Left > Page 8396 Pin Description Circuit 1 LEFT REAR SPEAKER (+) X51 18DG/DB Pin Description Circuit 1 AMPLIFIED LEFT REAR SPEAKER (+) X205 18GY/LG 2-3 LEFT REAR SPEAKER (-) X57 18DG/BR 3 AMPLIFIED LEFT REAR SPEAKER (-) X295 18GY/DG Component Location - 55 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Left > Page 8397 Component Location - 56 Speaker-Liftgate Component ID: 333 Component : SPEAKER-LIFTGATE Connector: Name : SPEAKER-LIFTGATE Color : LT. GRAY # of pins : 4 Qualifier : (EXCEPT BASE) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Left > Page 8398 Pin Description Circuit 1 AMPLIFIED LIFTGATE SPEAKER 1 (+) X214 18DG/DB 2 AMPLIFIED LIFTGATE SPEAKER 1 (-) X284 18DG/TN 3 AMPLIFIED LIFTGATE SPEAKER 2 (+) X212 18GY/DB 4 AMPLIFIED LIFTGATE SPEAKER 2 (-) X282 18GY/TN Component Location - 67 Speaker-Right Front Door Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Left > Page 8399 Component ID: 334 Component : SPEAKER-RIGHT FRONT DOOR Connector: Name : SPEAKER-RIGHT FRONT DOOR Color : WHITE # of pins : 3 Pin Description Circuit 1 RIGHT FRONT DOOR SPEAKER (+) X202 18DG/VT Pin Description Circuit 1 AMPLIFIED RIGHT FRONT DOOR SPEAKER (+) X202 18DG/VT 2-3 RIGHT FRONT DOOR SPEAKER (-) X292 18DG/YL 3 AMPLIFIED RIGHT FRONT DOOR SPEAKER (-) X292 18DG/YL Component Location - 53 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Left > Page 8400 Speaker-Right Rear Component ID: 335 Component : SPEAKER-RIGHT REAR Connector: Name : SPEAKER-RIGHT REAR Color : WHITE # of pins : 3 Pin Description Circuit Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Left > Page 8401 1 RIGHT REAR SPEAKER (+) X52 18GY/DB Pin Description Circuit 1 AMPLIFIED RIGHT REAR SPEAKER (+) X206 18DG/LG 2-3 RIGHT REAR SPEAKER (-) X58 18GY/OR 3 AMPLIFIED RIGHT REAR SPEAKER (-) X296 18DG/GY Component Location - 55 Component Location - 56 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Left > Page 8402 Speaker-Subwoofer Component ID: 336 Component : SPEAKER-SUBWOOFER Connector: Name : SPEAKER-SUBWOOFER Color : WHITE # of pins : 10 Qualifier : (PREMIUM) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Left > Page 8403 Pin Description Circuit 1 POWER ANTENNA SIGNAL X60 20GY/RD 2 GROUND Z960 16BK/LB 3-4-5 FUSED B(+) (I.O.D.) A419 18RD/DG 6-7 AMPLIFIED LEFT REAR SPEAKER (+) X205 18GY/LG 8 AMPLIFIED LEFT REAR SPEAKER (-) X295 18GY/DG 9 AMPLIFIED RIGHT REAR SPEAKER (+) X206 18DG/LG 10 AMPLIFIED RIGHT REAR SPEAKER (-) X296 18DG/LB 10 AMPLIFIED RIGHT REAR SPEAKER (-) X296 18DG/GY Component Location - 63 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door Speaker: Service and Repair Front Door Removal REMOVAL 1. Using trim stick C-4755, find service notch (1) located at the bottom of speaker grille and pry up speaker grille. 2. Remove two screws attaching speaker to door panel (3). 3. Remove two screws attaching speaker (2) to door module (1). 4. Disconnect wire connector. Installation INSTALLATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door > Page 8406 1. Connect wire connector. 2. Install speaker (2) into panel (3) and install two screws into door panel. 3. Install two screws into trim panel (1). 4. Install speaker grille (1) onto trim panel (3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door > Page 8407 Speaker: Service and Repair Rear Door Removal REMOVAL 1. Using trim stick C-4755, find service notch (1) located at the bottom of speaker grille and pry up speaker grille. 2. Remove two screws attaching speaker to door panel (3). 3. Remove two screws attaching speaker (2) to door module (1). 4. Disconnect wire connector. Installation INSTALLATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door > Page 8408 1. Place speaker (2) up to door module (3). 2. Connect wire connector. 3. Install screws fastening speaker to door module. 4. Place speaker grille (1) up to door module and install fasteners. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door > Page 8409 Speaker: Service and Repair Speaker Removal REMOVAL DOOR SPEAKERS 1. Using an approved flat blade tool find the service notch located at the bottom of speaker grille and pry up speaker grille. 2. Remove the four screws attaching the speaker (2) to door panel (3). 3. Disconnect the electrical connector and remove the speaker. INSTRUMENT PANEL SPEAKER Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door > Page 8410 1. Disconnect and isolate the battery negative cable. 2. Remove instrument panel (2) top cover. 3. Remove speaker retaining screws. 4. Remove speaker (1) and disconnect wire harness connector. REAR SPEAKER - LIFTGATE 1. Disconnect and isolate the battery negative cable. 2. Remove the speaker enclosure fasteners. 3. Remove speaker and disconnect the electrical harness connector. REAR SUBWOOFER Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door > Page 8411 1. Disconnect and isolate the battery negative cable. 2. Remove the right quarter trim panel. 3. Remove the subwoofer mounting fasteners. 4. Disconnect the electrical harness connector. 5. Remove the speaker. Installation INSTALLATION DOOR SPEAKERS 1. Connect wire connector. 2. Install speaker (2) into the door panel (3) opening and install the four screws into door panel. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door > Page 8412 3. Install speaker grille (1) onto trim panel. INSTRUMENT PANEL SPEAKER 1. Connect wire harness connector to speaker (1). 2. Install speaker screws. 3. Install instrument panel (2) top cover. 4. Connect the battery negative cable. REAR SPEAKER - TAILGATE 1. Connect electrical harness connector and position speaker. 2. Install and tighten mounting fasteners. 3. Connect battery negative cable. REAR SUBWOOFER Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door > Page 8413 1. Position the speaker and connect the electrical harness connector. 2. Install the subwoofer mounting fasteners. 3. Install the right rear quarter trim panel. 4. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Refrigerator > Component Information > Technical Service Bulletins > Customer Interest for Refrigerator: > 24-005-07 > Jul > 07 > Accessories - Chill Zone Won't Stay Cold Refrigerator: Customer Interest Accessories - Chill Zone Won't Stay Cold NUMBER: 24-005-07 GROUP: Heating & Air Conditioning DATE: July 19,2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-005-06 REV. A, DATED SEPTEMBER 14, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES 2008 MODELS AND REMOVAL OF CLEAN POINTS. SUBJECT: Chill Zone Does Not Stay Cold Or Mode Door Does Not Stay In Position OVERVIEW: This bulletin involves applying a piece of sticky back foam tape to the chill zone mode door. NOTE: For detailed Chill Zone operating information consult the Owner Manual. MODELS: **2007- (PM) Caliber 2008** SYMPTOM/CONDITION: The customer may describe that chill zone does not stay cold or that the chill zone mode door does not stay in position. DIAGNOSIS: If the vehicle exhibits the symptom/condition listed above perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. Open glove box. 3. Using trim stick (C-4755) remove the chill zone mode door. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Refrigerator > Component Information > Technical Service Bulletins > Customer Interest for Refrigerator: > 24-005-07 > Jul > 07 > Accessories - Chill Zone Won't Stay Cold > Page 8422 4. Apply a piece of sticky back open cell foam tape 10 mm (.39 inch) tall by 10 mm (.39 inch) wide by 50 mm (2 inch) long to the mode door facing upward. Position the tape as shown in (Fig 1). 5. Install the chill zone mode door. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Refrigerator > Component Information > Technical Service Bulletins > Customer Interest for Refrigerator: > 24-005-06A > Sep > 06 > Accessories - Chill Zone Does Not Stay Cold Refrigerator: Customer Interest Accessories - Chill Zone Does Not Stay Cold NUMBER: 24-005-06 REV. A GROUP: Heating & Air Conditioning DATE: September 14, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-005-06, DATED JUNE 14, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES A NEW VEHICLE BUILD DATE. SUBJECT: Chill Zone Does Not Stay Cold Or Chill Zone Mode Door Does Not Stay In Position OVERVIEW: This bulletin involves applying a piece of sticky back foam tape to the chill zone mode door. NOTE: For detail Chill Zone operating information consult the Owner Manual. MODELS: 2007 (PM) Caliber NOTE: **This bulletin applies to vehicles built on or before August 20, 2006 (MDH 0820XX).** SYMPTOM/CONDITION: The customer may describe that chill zone does not stay cold or that the chill zone mode door does not stay in position. DIAGNOSIS: If the vehicle exhibits the symptom/condition listed above perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. Open glove box. 3. Using trim stick (C-4755) remove the chill zone mode door. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Refrigerator > Component Information > Technical Service Bulletins > Customer Interest for Refrigerator: > 24-005-06A > Sep > 06 > Accessories - Chill Zone Does Not Stay Cold > Page 8427 4. Apply a piece of sticky back open cell foam tape 10 mm (.39 inch) tall by 10 mm (.39 inch) wide by 50 mm (2 inch) long to the mode door facing upward. Position the tape as shown in (Fig. 1). 5. Install the chill zone mode door. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Refrigerator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerator: > 24-005-07 > Jul > 07 > Accessories - Chill Zone Won't Stay Cold Refrigerator: All Technical Service Bulletins Accessories - Chill Zone Won't Stay Cold NUMBER: 24-005-07 GROUP: Heating & Air Conditioning DATE: July 19,2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-005-06 REV. A, DATED SEPTEMBER 14, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES 2008 MODELS AND REMOVAL OF CLEAN POINTS. SUBJECT: Chill Zone Does Not Stay Cold Or Mode Door Does Not Stay In Position OVERVIEW: This bulletin involves applying a piece of sticky back foam tape to the chill zone mode door. NOTE: For detailed Chill Zone operating information consult the Owner Manual. MODELS: **2007- (PM) Caliber 2008** SYMPTOM/CONDITION: The customer may describe that chill zone does not stay cold or that the chill zone mode door does not stay in position. DIAGNOSIS: If the vehicle exhibits the symptom/condition listed above perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. Open glove box. 3. Using trim stick (C-4755) remove the chill zone mode door. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Refrigerator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerator: > 24-005-07 > Jul > 07 > Accessories - Chill Zone Won't Stay Cold > Page 8433 4. Apply a piece of sticky back open cell foam tape 10 mm (.39 inch) tall by 10 mm (.39 inch) wide by 50 mm (2 inch) long to the mode door facing upward. Position the tape as shown in (Fig 1). 5. Install the chill zone mode door. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Refrigerator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerator: > 24-005-06A > Sep > 06 > Accessories - Chill Zone Does Not Stay Cold Refrigerator: All Technical Service Bulletins Accessories - Chill Zone Does Not Stay Cold NUMBER: 24-005-06 REV. A GROUP: Heating & Air Conditioning DATE: September 14, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-005-06, DATED JUNE 14, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES A NEW VEHICLE BUILD DATE. SUBJECT: Chill Zone Does Not Stay Cold Or Chill Zone Mode Door Does Not Stay In Position OVERVIEW: This bulletin involves applying a piece of sticky back foam tape to the chill zone mode door. NOTE: For detail Chill Zone operating information consult the Owner Manual. MODELS: 2007 (PM) Caliber NOTE: **This bulletin applies to vehicles built on or before August 20, 2006 (MDH 0820XX).** SYMPTOM/CONDITION: The customer may describe that chill zone does not stay cold or that the chill zone mode door does not stay in position. DIAGNOSIS: If the vehicle exhibits the symptom/condition listed above perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. Open glove box. 3. Using trim stick (C-4755) remove the chill zone mode door. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Refrigerator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerator: > 24-005-06A > Sep > 06 > Accessories - Chill Zone Does Not Stay Cold > Page 8438 4. Apply a piece of sticky back open cell foam tape 10 mm (.39 inch) tall by 10 mm (.39 inch) wide by 50 mm (2 inch) long to the mode door facing upward. Position the tape as shown in (Fig. 1). 5. Install the chill zone mode door. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations Alarm Module: Locations Component ID: 156 Component : MODULE-INTRUSION TRANSCEIVER Connector: Name : MODULE-INTRUSION TRANSCEIVER C1 Color : BLACK # of pins : 6 Pin Description Circuit 1 FUSED B(+) (I.O.D.) A415 20RD/TN 2-3 CAN B BUS (+) D55 20WT/OR 4 CAN B BUS (-) D54 20WT/PK 5 SIREN SIGNAL CONTROL D96 20WT/BR 6 GROUND Z941 20BK/WT Component Location - 41 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 8443 Component Location - 43 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 8444 Connector: Name : MODULE-INTRUSION TRANSCEIVER C2 Color : BLACK # of pins : 3 Pin Description Circuit 1-2 COURTESY LAMPS DRIVER M24 20YL/WT 3 GROUND Z941 20BK/WT Component Location - 41 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 8445 Component Location - 43 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 8446 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 8447 Alarm Module: Diagrams Component ID: 156 Component : MODULE-INTRUSION TRANSCEIVER Connector: Name : MODULE-INTRUSION TRANSCEIVER C1 Color : BLACK # of pins : 6 Pin Description Circuit 1 FUSED B(+) (I.O.D.) A415 20RD/TN 2-3 CAN B BUS (+) D55 20WT/OR 4 CAN B BUS (-) D54 20WT/PK 5 SIREN SIGNAL CONTROL D96 20WT/BR 6 GROUND Z941 20BK/WT Component Location - 41 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 8448 Component Location - 43 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 8449 Connector: Name : MODULE-INTRUSION TRANSCEIVER C2 Color : BLACK # of pins : 3 Pin Description Circuit 1-2 COURTESY LAMPS DRIVER M24 20YL/WT 3 GROUND Z941 20BK/WT Component Location - 41 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 8450 Component Location - 43 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 8451 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Component ID: 161 Component : MODULE-SENTRY KEY REMOTE ENTRY/WCM Connector: Name : MODULE-SENTRY KEY REMOTE ENTRY/WCM Color : BLACK # of pins : 8 Pin Description Circuit 1 IGNITION SWITCH SENSE G20 20VT/BR 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4 GROUND Z937 20BK/YL 5 FUSED B(+) (I.O.D.) A411 20RD/LG 6 CAN B BUS (+) D55 20WT/OR 7 CAN B BUS (-) D54 20WT/PK 8-Component Location - 28 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 8455 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 8456 Keyless Entry Module: Diagrams Component ID: 161 Component : MODULE-SENTRY KEY REMOTE ENTRY/WCM Connector: Name : MODULE-SENTRY KEY REMOTE ENTRY/WCM Color : BLACK # of pins : 8 Pin Description Circuit 1 IGNITION SWITCH SENSE G20 20VT/BR 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4 GROUND Z937 20BK/YL 5 FUSED B(+) (I.O.D.) A411 20RD/LG 6 CAN B BUS (+) D55 20WT/OR 7 CAN B BUS (-) D54 20WT/PK 8-Component Location - 28 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 8457 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Description and Operation > Description Keyless Entry Module: Description and Operation Description DESCRIPTION When a PCM and the SKREEM are replaced at the same time, perform the following steps in order: 1. Program the new PCM. 2. Program the new SKREEM. 3. Replace all ignition keys and program them to the new SKREEM. The Sentry Key REmote Entry Module (SKREEM) is sometimes referred to as the Wireless Control Module (WCM). The SKREEM/WCM is the primary component of the Sentry Key Immobilizer System (SKIS). It is also the receiver for the Remote Keyless Entry (RKE) system and the Tire Pressure Monitor (TPM) system. The SKREEM/WCM is located on the steering column, around the ignition lock cylinder housing and is concealed beneath the steering column shrouds. The molded black plastic housing for the SKREEM/WCM has an integral molded plastic halo-like antenna ring (3) that extends from one side. When the SKREEM/WCM is properly installed, the antenna ring is oriented around the ignition lock cylinder housing. A single connector (4) is located next to the antenna ring on the SKREEM/WCM housing (3). A molded plastic mounting tab (2) on the SKREEM/WCM housing secures the unit to the steering column. The SKREEM/WCM is connected to the vehicle electrical system through the instrument panel wire harness. The SKREEM/WCM cannot be adjusted or repaired. If faulty or damaged, the entire SKREEM unit must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Description and Operation > Description > Page 8460 Keyless Entry Module: Description and Operation Operation OPERATION The Sentry Key REmote Entry Module (SKREEM), sometimes referred to as the Wireless Control Module (WCM), contains a Radio Frequency (RF) transceiver and a microprocessor. The SKREEM/WCM transmits RF signals to, and receives RF signals from the Sentry Key transponder through a tuned antenna enclosed within the molded plastic antenna ring integral to the SKREEM/WCM housing. If this antenna ring is not mounted properly around the ignition lock cylinder housing, communication problems between the SKREEM/WCM and the transponder may arise. These communication problems will result in Sentry Key transponder-related faults. The SKREEM also serves as the Remote Keyless Entry (RKE) RF receiver and, if the vehicle is so equipped, the receiver for the Tire Pressure Monitoring (TPM) system. The SKREEM/WCM communicates over the Controller Area Network (CAN) data bus with the Electromechanical Instrument Cluster (EMIC) (sometimes referred to as the Cab Compartment Node (CCN), the Powertrain Control Module (PCM), and/or the diagnostic scan tool. The SKREEM/WCM retains in memory the ID numbers of any Sentry Key transponder that is programmed into it. A maximum of eight Sentry Key transponders can be programmed into the SKREEM/WCM. For added system security, each SKREEM/WCM is programmed with a unique Secret Key code. This code is stored in memory, sent over the CAN data bus to the PCM, and is encoded to the transponder of every Sentry Key that is programmed into the SKREEM/WCM. Therefore, the Secret Key code is a common element that is found in every component of the Sentry Key Immobilizer System (SKIS). Another security code, called a PIN, is used to gain access to the SKREEM/WCM Secured Access Mode. The Secured Access Mode is required during service to perform the SKIS initialization and Sentry Key transponder programming procedures. The SKREEM/WCM also stores the Vehicle Identification Number (VIN) in its memory, which it learns through a CAN data bus message from the PCM during SKIS initialization. NOTE: After a SKREEM/WCM is replaced, the ignition/transponder keys need to be programmed to the new SKREEM/WCM. Follow the directions on the diagnostic scan tool. The transponder key for the SKREES/SKIM and the RKE will both be programmed during this operation. There is no need to program the fob of the key for RKE functionality once the transponder key is programmed to the new SKREEM/WCM. In the event that a SKREEM/WCM replacement is required, the Secret Key code can be transferred to the new SKREEM/WCM from the PCM using the diagnostic scan tool and the SKIS initialization procedure. Proper completion of the SKIS initialization will allow the existing Sentry Keys to be programmed into the new SKREEM/WCM so that new keys will not be required. In the event that the original Secret Key code cannot be recovered, SKREEM/WCM replacement will also require new Sentry Keys. The diagnostic scan tool will alert the technician during the SKIS initialization procedure if new Sentry Keys are required. When the ignition switch is turned to the On position, the SKREEM/WCM transmits an RF signal to the transponder in the ignition key. The SKREEM/WCM then waits for an RF signal response from the transponder. If the response received identifies the key as valid, the SKREEM/WCM sends a valid key message to the PCM over the CAN data bus. If the response received identifies the key as invalid or if no response is received from the key transponder, the SKREEM/WCM sends an invalid key message to the PCM. The PCM will enable or disable engine operation based upon the status of the SKREEM/WCM messages. It is important to note that the default condition in the PCM is an invalid key; therefore, if no message is received from the SKREEM/WCM by the PCM, the engine will be disabled and the vehicle immobilized after two seconds of running. The SKREEM/WCM also sends security indicator status messages to the EMIC/CCN over the CAN data bus to tell the EMIC/CCN how to operate the security indicator. The security indicator status message from the SKREEM/WCM tells the EMIC/CCN to turn the indicator on for about three seconds each time the ignition switch is turned to the On position as a bulb test. After completion of the bulb test, the SKREEM/WCM sends security indicator status messages to the EMIC/CCN to turn the indicator off, turn the indicator on, or to flash the indicator on and off. If the security indicator flashes or stays on solid after the bulb test, it signifies a SKIS fault. If the SKREEM/WCM detects a system malfunction and/or the SKIS has become inoperative, the security indicator will stay on solid. If the SKREEM/WCM detects an invalid key or if a key transponder-related fault exists, the security indicator will flash. If the vehicle is equipped with the Customer Learn transponder programming feature, the SKREEM/WCM will also send messages to the EMIC/CCN to flash the security indicator whenever the Customer Learn programming mode is being utilized. The SKIS performs a self-test each time the ignition switch is turned to the On position, and will store fault information in the form of a Diagnostic Trouble Code (DTC) in SKREEM/WCM memory if a system malfunction is detected. The SKREEM/WCM can be diagnosed, and any stored DTC can be retrieved using a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Description and Operation > Page 8461 Keyless Entry Module: Testing and Inspection REMOTE KEYLESS ENTRY MODULE The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic information. Refer to the appropriate wiring information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Removal Keyless Entry Module: Service and Repair Removal REMOVAL NOTE: The steering wheel does not have to be removed to service the SKREEM/WCM. NOTE: The Steering Column Control Module (SCCM) assembly, which consists of the left/right multi-function switches and the clockspring, does not have to be removed to service the SKREEM/WCM. There is an access hole in the top of the right multi-function switch to access the mounting screw (2). 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. 2. Remove the upper and lower steering column shrouds. 3. Remove the SKREEM/WCM mounting screw (2) on the ignition lock assembly and separate the SKREEM/WCM (3) from the ignition lock assembly. 4. Disconnect the SKREEM/WCM electrical connector (4). 5. Remove SKREEM/WCM (1 and 3) from column (2). When a PCM and the SKREEM/WCM are replaced at the same time, perform the following steps in order. - Program the new PCM. - Program the new SKREEM/WCM. - Replace all ignition keys and program them to the new SKREEM/WCM. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Removal > Page 8464 Keyless Entry Module: Service and Repair Installation INSTALLATION When a PCM and the SKREEM/WCM are replaced at the same time, perform the following steps in order. - Program the new PCM. - Program the new SKREEM/WCM. - Replace all ignition keys and program them to the new SKREEM/WCM. 1. Position the SKREEM/WCM (3) on the ignition lock housing and install the retaining screw (2). 2. Connect the SKREEM/WCM electrical connector (4). NOTE: On vehicles equipped with the optional Sentry Key Immobilizer System (SKIS), when the SKREEM is replaced with a new unit, a diagnostic scan tool MUST be used to initialize the new SKREEM and to program at least two Sentry Key transponders before the vehicle can be operated. 3. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Diagrams Navigation Module: Diagrams Component ID: 164 Component : MODULE-TRAFFIC INFORMATION RECEIVER Connector: Name : MODULE-TRAFFIC INFORMATION RECEIVER Color : # of pins : 12 Pin Description Circuit 1-2 CAN B BUS (+) D55 20WT/OR 3-4-5-6 FUSED B(+) (I.O.D.) A413 20RD/LB 7 GROUND Z909 20BK 8 CAN B BUS (-) D54 20WT/PK 9-10 - 11 - 12 - - Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations Voice Activation Module: Locations Component ID: 152 Component : MODULE-HANDS FREE Connector: Name : MODULE-HANDS FREE Color : DK. GRAY # of pins : 22 Pin Description Circuit 1 FUSED B(+) (I.O.D.) A417 18RD/DG 2-3-4 CAN B BUS (-) D54 20WT/PK 5 MICROPHONE 2 IN (+) X722 20LB/DG 6-7-- 8 LEFT AUDIO OUTPUT X703 22DG/OR 9 RIGHT AUDIO OUTPUT X704 22DG/PK 10 COMMON AUDIO OUTPUT X795 22DG/BK 11 - 12 - 13 - 14 CAN B BUS (+) D55 20WT/OR 15 VOICE RECOGNITION/PHONE SWITCH SIGNAL X730 20GY/YL 16 MICROPHONE 1 IN (+) X712 20DG/LB 17 MICROPHONE IN (-) X792 20LB/TN 18 - 19 - 20 MICROPHONE FEED X793 20DG/YL 21 SENSOR GROUND X835 20OR/BK 22 GROUND Z937 18BK/YL Component Location - 23 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations > Page 8471 Fig. 23 Component Location - 24 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations > Page 8472 Component Location - 26 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations > Page 8473 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations > Page 8474 Voice Activation Module: Diagrams Component ID: 152 Component : MODULE-HANDS FREE Connector: Name : MODULE-HANDS FREE Color : DK. GRAY # of pins : 22 Pin Description Circuit 1 FUSED B(+) (I.O.D.) A417 18RD/DG 2-3-4 CAN B BUS (-) D54 20WT/PK 5 MICROPHONE 2 IN (+) X722 20LB/DG 6-7-- 8 LEFT AUDIO OUTPUT X703 22DG/OR 9 RIGHT AUDIO OUTPUT X704 22DG/PK 10 COMMON AUDIO OUTPUT X795 22DG/BK 11 - 12 - 13 - 14 CAN B BUS (+) D55 20WT/OR 15 VOICE RECOGNITION/PHONE SWITCH SIGNAL X730 20GY/YL 16 MICROPHONE 1 IN (+) X712 20DG/LB 17 MICROPHONE IN (-) X792 20LB/TN 18 - 19 - 20 MICROPHONE FEED X793 20DG/YL 21 SENSOR GROUND X835 20OR/BK 22 GROUND Z937 18BK/YL Component Location - 23 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations > Page 8475 Fig. 23 Component Location - 24 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations > Page 8476 Component Location - 26 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations > Page 8477 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Description and Operation Integrated Accessory Switch Assembly: Description and Operation DESCRIPTION There is an Accessory Switch Bank Module (ASBM) located in the instrument panel center stack just below the heater a/c control. Included in this switch bank are: - Electronic Stability Program (ESP)/Traction Control Switch (TCS) Off (if equipped) - Hazard Switch (all models) - Heated Seat Switch (if equipped) - Passenger Airbag Disabled Lamp (PADL) Indicator (if equipped with OCS) The BUX version of the ASBM will vary from the domestic a bit. Following are the various BUX switches: - Anti-Skid Control (ASC) (if equipped) - This is the same as the ESP/TCS off switch in the domestic version. - Hazard Switch (all models) - Heated Seat Switch (if equipped) - Headlamp Leveling Switch (if equipped) Each individual switch is not available for service replacement. If one or more switches are inoperative, the entire ASBM must be replaced. To diagnose the ASBM switches, use a scan tool and the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Service and Repair > Removal Integrated Accessory Switch Assembly: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel center bezel. 3. Remove the screws to the Accessory Switch Bank Module (ASBM) (4). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Service and Repair > Removal > Page 8484 Integrated Accessory Switch Assembly: Service and Repair Installation INSTALLATION 1. Position the Accessory Switch Bank Module (ASBM) (4) in the center bezel. 2. Install the screws to the ASBM. 3. Install the instrument panel center bezel. 4. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Description Remote Switch: Description and Operation Description DESCRIPTION Two rocker-type switches (if equipped) are mounted on the back (instrument panel side) of the steering wheel spokes. The switch on the left spoke is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right spoke is the volume control switch and has volume up, and volume down functions. The switch on the right spoke also includes a "mode" control that allows the driver to sequentially select AM radio, FM radio, cassette player, CD player or CD changer (if equipped). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Description > Page 8489 Remote Switch: Description and Operation Operation OPERATION These switches are resistor multiplexed units that are hard-wired to the Cab Compartment Node (CCN) through the clockspring. The CCN sends the proper messages on the Controller Area Network (CAN) data bus network to the radio receiver. For diagnosis of the CCN or the CAN data bus, the use of a scan tool and the proper Diagnostic Procedures manual are recommended. For more information on the operation of the remote radio switch controls, refer to the owner's manual in the vehicle glove box. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Page 8490 Remote Switch: Testing and Inspection REMOTE SWITCHES WARNING: On vehicles equipped with airbags, refer to electrical, restraints before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. Any diagnosis of the Audio system should begin with the use of the scan tool. For information on the use of the scan tool, refer to the appropriate Diagnostic Manual. For complete circuit diagrams, refer to the appropriate wiring information. 1. Disconnect and isolate the battery negative cable. 2. Remove the remote radio switch(es) from the steering wheel. 3. Use an ohmmeter to check the switch resistance as shown in the Remote Radio Switch Test table NOTE: The right remote radio switch back is white in color. The left switch back is black in color. The right/left remote radio switch orientation is with the steering wheel installed, and driver in driver's seat. 4. If the switch resistance checks OK, go to STEP 5. If not OK, replace the faulty switch. 5. Check for continuity between the ground circuit cavity of the switch wire harness connector and a good ground. There should be continuity. If OK, go to STEP 6. If not OK, repair the open circuit as required. 6. Unplug the connector from the Cab Compartment Node (CCN). Check for continuity between the radio control circuit cavity of the remote radio switch wire harness connector and a good ground. There should be no continuity. If OK, go to STEP 7. If not OK, repair the short circuit as required. 7. Check for continuity between the radio control circuit cavities of the remote radio switch wire harness connector and the CCN wire harness connector. There should be continuity. If OK, refer to the proper Diagnostic Procedures manual to test the CCN and the CAN data bus. If not OK, repair the open circuit as required. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Service and Repair > Removal Remote Switch: Service and Repair Removal REMOVAL WARNING: On vehicles equipped with airbags, refer to electrical, restraints before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. 1. Disconnect and isolate the battery negative cable. 2. Remove the driver side airbag. 3. Remove the steering wheel. 4. Unplug the wire harness connector from the remote radio switch. 5. Remove steering wheel rear cover. 6. Remove the remote radio switch from the steering wheel by depressing tabs on each side of each switch. NOTE: The right remote radio switch back is white in color. The left switch back is black in color. The right/left remote radio switch orientation is with the steering wheel installed, and driver in driver's seat. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Service and Repair > Removal > Page 8493 Remote Switch: Service and Repair Installation INSTALLATION WARNING: On vehicles equipped with airbags, refer to electrical, restraints before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. 1. Install remote radio switch to the steering wheel. 2. Install steering wheel rear cover. 3. Connect the wire harness to the remote radio switch. 4. Install the steering wheel. 5. Install the driver side airbag. 6. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Description Steering Mounted Controls Communication Module: Description and Operation Description DESCRIPTION This vehicle is equipped with a Steering Column Control Module (SCCM) The SCCM is secured near the top of the steering column below the steering wheel and is completely concealed beneath the steering column shrouds. It is installed as a modular unit that supports the left (lighting) multi-function switch (1) and right (wiper) multi-function switch (6). The controls for each of these switches extend through appropriate clearance holes provided in the steering column shrouds. The microprocessor-based Steering Control Module (SCM) (2) utilizes integrated circuitry and information carried on the Controller Area Network (CAN) data bus along with several hard wired analog and multiplexed inputs to monitor both the right and left multi-function switches. The SCCM uses a Local Interconnect Network (LIN) data bus for exterior lighting and wiper functions. The LIN data is sent to the Cab Compartment Node (CCN) and the CCN then sends it out on the CAN data bus. The SCCM is available for service replacement as a unit or each individual component: - Clockspring (with integral Steering Angle Sensor if equipped) - Left Multi-Function Switch - Right Multi-Function Switch Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Description > Page 8498 Steering Mounted Controls Communication Module: Description and Operation Operation OPERATION The Steering Control Module (SCM) communicates over the Local Interconnect Network (LIN) data bus with other electronic modules in the vehicle and/or a diagnostic scan tool. The horn switch circuits pass through the clockspring to the Cab Compartment Node (CCN) and the CCN sends a CAN message to the Totally Integrated Power Module (TIPM) to control the horn. The CCN stores Diagnostic Trouble Codes (DTC's) for the SCM. The right (wiper) multi-function switch has several inputs to the CCN. The SCM is connected to a fused B(+) circuit and receives a path to ground at all times. These connections allow it to remain functional regardless of the ignition switch position. The driver airbag squib circuits of the clockspring, the horn, and the speed control switch circuits pass through the SCM, but the SCM does not monitor, and has no control outputs related to these circuits. Any other input to the SCM that would cause a vehicle system to function but does not require that the ignition switch be in the On position, such as turning on the lights or sounding the horn, prompts the SCM to wake up and transmit on the CAN data bus. The most reliable, efficient, and accurate means to diagnose the SCM, the CAN data bus, the hard wired inputs or the electronic communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. The integral SCM is not available for separate service replacement. If found inoperative or defective, the entire left (lighting) multi-function switch must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Locations Trailer Connector: Locations Component ID: 49 Component : CONNECTOR-TRAILER TOW Connector: Name : CONNECTOR-TRAILER TOW Color : DK. GRAY # of pins : 6 Pin Description Circuit 1-2 FUSED B(+) A100 18RD/VT 3-4-5-6-Component Location - 60 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Locations > Page 8503 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: Provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8506 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8507 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8508 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8509 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8510 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8511 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8512 5. Release the Secondary Terminal Lock, if required (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8513 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8514 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8515 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8516 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8517 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8518 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8519 Trailer Connector: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8520 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8521 STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8522 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8523 Trailer Connector: Connector Views Component ID: 49 Component : CONNECTOR-TRAILER TOW Connector: Name : CONNECTOR-TRAILER TOW Color : DK. GRAY # of pins : 6 Pin Description Circuit 1-2 FUSED B(+) A100 18RD/VT 3-4-5-6-Component Location - 60 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8524 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions Trailer Lamps: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: Provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8529 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8530 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8531 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8532 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8533 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8534 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8535 5. Release the Secondary Terminal Lock, if required (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8536 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8537 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8538 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8539 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8540 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8541 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8542 Trailer Lamps: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8543 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8544 STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8545 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Locations Trailer Connector: Locations Component ID: 49 Component : CONNECTOR-TRAILER TOW Connector: Name : CONNECTOR-TRAILER TOW Color : DK. GRAY # of pins : 6 Pin Description Circuit 1-2 FUSED B(+) A100 18RD/VT 3-4-5-6-Component Location - 60 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Locations > Page 8549 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: Provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8552 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8553 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8554 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8555 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8556 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8557 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8558 5. Release the Secondary Terminal Lock, if required (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8559 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8560 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8561 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8562 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8563 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8564 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8565 Trailer Connector: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8566 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8567 STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8568 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8569 Trailer Connector: Connector Views Component ID: 49 Component : CONNECTOR-TRAILER TOW Connector: Name : CONNECTOR-TRAILER TOW Color : DK. GRAY # of pins : 6 Pin Description Circuit 1-2 FUSED B(+) A100 18RD/VT 3-4-5-6-Component Location - 60 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8570 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Voice Activation System > Voice Activation Module > Component Information > Locations Voice Activation Module: Locations Component ID: 152 Component : MODULE-HANDS FREE Connector: Name : MODULE-HANDS FREE Color : DK. GRAY # of pins : 22 Pin Description Circuit 1 FUSED B(+) (I.O.D.) A417 18RD/DG 2-3-4 CAN B BUS (-) D54 20WT/PK 5 MICROPHONE 2 IN (+) X722 20LB/DG 6-7-- 8 LEFT AUDIO OUTPUT X703 22DG/OR 9 RIGHT AUDIO OUTPUT X704 22DG/PK 10 COMMON AUDIO OUTPUT X795 22DG/BK 11 - 12 - 13 - 14 CAN B BUS (+) D55 20WT/OR 15 VOICE RECOGNITION/PHONE SWITCH SIGNAL X730 20GY/YL 16 MICROPHONE 1 IN (+) X712 20DG/LB 17 MICROPHONE IN (-) X792 20LB/TN 18 - 19 - 20 MICROPHONE FEED X793 20DG/YL 21 SENSOR GROUND X835 20OR/BK 22 GROUND Z937 18BK/YL Component Location - 23 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Voice Activation System > Voice Activation Module > Component Information > Locations > Page 8575 Fig. 23 Component Location - 24 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Voice Activation System > Voice Activation Module > Component Information > Locations > Page 8576 Component Location - 26 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Voice Activation System > Voice Activation Module > Component Information > Locations > Page 8577 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Voice Activation System > Voice Activation Module > Component Information > Locations > Page 8578 Voice Activation Module: Diagrams Component ID: 152 Component : MODULE-HANDS FREE Connector: Name : MODULE-HANDS FREE Color : DK. GRAY # of pins : 22 Pin Description Circuit 1 FUSED B(+) (I.O.D.) A417 18RD/DG 2-3-4 CAN B BUS (-) D54 20WT/PK 5 MICROPHONE 2 IN (+) X722 20LB/DG 6-7-- 8 LEFT AUDIO OUTPUT X703 22DG/OR 9 RIGHT AUDIO OUTPUT X704 22DG/PK 10 COMMON AUDIO OUTPUT X795 22DG/BK 11 - 12 - 13 - 14 CAN B BUS (+) D55 20WT/OR 15 VOICE RECOGNITION/PHONE SWITCH SIGNAL X730 20GY/YL 16 MICROPHONE 1 IN (+) X712 20DG/LB 17 MICROPHONE IN (-) X792 20LB/TN 18 - 19 - 20 MICROPHONE FEED X793 20DG/YL 21 SENSOR GROUND X835 20OR/BK 22 GROUND Z937 18BK/YL Component Location - 23 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Voice Activation System > Voice Activation Module > Component Information > Locations > Page 8579 Fig. 23 Component Location - 24 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Voice Activation System > Voice Activation Module > Component Information > Locations > Page 8580 Component Location - 26 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Voice Activation System > Voice Activation Module > Component Information > Locations > Page 8581 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > System Information > Description and Operation > Description Body Control Systems: Description and Operation Description DESCRIPTION The primary on-board communication network between microprocessor-based electronic control modules in this vehicle is the Controller Area Network (CAN) data bus system. A data bus network minimizes redundant wiring connections; and, at the same time, reduces wire harness complexity, sensor current loads and controller hardware by allowing each sensing device to be connected to only one module (also referred to as a node). Each node reads, then broadcasts its sensor data over the bus for use by all other nodes requiring that data. Each node ignores the messages on the bus that it cannot use. The CAN bus is a two-wire multiplex system. Multiplexing is any system that enables the transmission of multiple messages over a single channel or circuit. The CAN bus is used for communication between most vehicle nodes. However, in addition to the CAN bus network, certain nodes may also be equipped with a Local Interface Network (LIN) data bus. The LIN data bus is a single wire low-speed system used to provide direct communication between a master module and certain switch or sensor inputs. There are actually three separate CAN bus systems used in the vehicle. They are designated: the CAN-B, the CAN-C and the Diagnostic CAN-C. The CAN-B and CAN-C systems provide on-board communication between all nodes in the vehicle. The CAN-C is the faster of the two systems providing near real-time communication (500 Kbps), but is less fault tolerant than the CAN-B system. The CAN-C is used exclusively for communications between critical powertrain and chassis nodes. The slower (83.3 Kbps), but more fault tolerant CAN-B system is used for communications between body and interior nodes. The CAN-B fault tolerance comes from its ability to revert to a single wire communication mode if there is a fault in the bus wiring. The added speed of the CAN data bus is many times faster than previous data bus systems. This added speed facilitates the addition of more electronic control modules or nodes and the incorporation of many new electrical and electronic features in the vehicle. The Diagnostic CAN-C bus is also capable of 500 Kbps communication, and is sometimes informally referred to as the CAN-D system to differentiate it from the other high speed CAN-C bus. The Diagnostic CAN-C is used exclusively for the transmission of diagnostic information between the Totally Integrated Power Module/Central GateWay (TIPM or TIPMCGW) and a diagnostic scan tool connected to the industry-standard 16-way Data Link Connector (DLC) located beneath the instrument panel on the driver side of the vehicle. The TIPM is located in the engine compartment near the battery. The central CAN gateway or hub module integral to the TIPM is connected to all three CAN buses. This gateway physically and electrically isolates the CAN buses from each other and coordinates the bi-directional transfer of messages between them. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > System Information > Description and Operation > Description > Page 8587 Body Control Systems: Description and Operation Operation OPERATION The Controller Area Network (CAN) data bus allows all electronic modules or nodes connected to the bus to share information with each other. Regardless of whether a message originates from a module on the low speed CAN-B bus or on the high speed CAN-C or CAN-D bus, the message structure and layout is similar, which allows the Totally Integrated Power Module/Central GateWay (TIPM or TIPMCGW) to process and transfer messages between the CAN buses. The TIPM also stores a Diagnostic Trouble Code (DTC) for certain bus network faults. All modules (also referred to as nodes) transmit and receive messages over one of these buses. Data exchange between nodes is achieved by serial transmission of encoded data messages. Each node can both send and receive serial data simultaneously. Bus messages are carried over the data bus in the form of Variable Pulse Width Modulated (VPWM) signals which, when the high and low voltage pulses are strung together, form a message. Each node uses arbitration to sort the message priority if two competing messages are attempting to be broadcast at the same time. The Electromechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) is the Local Interface Network (LIN) master module in this vehicle and it gathers information from the compass module, the instrument panel switch bank, the Steering Control Module (SCM), and the Heated Seat Module (HSM) through the LIN data bus. There is also LIN data bus communication between the individual Tire Pressure Monitor (TPM) transponders and the Sentry Key REmote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM). Both the EMIC and the SKREEM either act directly upon the information received through the LIN data bus or relay the information to other nodes in the vehicle using electronic messages placed on the CAN-B bus. The voltage network used to transmit messages requires biasing and termination. Each module on the CAN bus network provides its own biasing and termination. Each node terminates the bus through a terminating resistor and a terminating capacitor. There are two types of nodes on the bus. The dominant node terminates the bus through a 1 KW resistor and a 3300 pF capacitor, typically resulting in about a 3300 ohm termination resistance. However, this resistance value may vary somewhat by application. The TIPM (or TIPMCGW) is the only dominant node in this network. A non-dominant (or recessive) node terminates the bus through an 11 KW resistor and a 330 pF capacitor, typically resulting in about a 10800 ohm termination resistance. The communication protocol being used for the CAN data bus is a non-proprietary, open standard adopted from the Bosch CAN Specification 2.0b. The CAN-C is the faster of the two primary buses in the CAN bus system, providing near real-time communication (500 Kbps). The CAN bus nodes are connected in parallel to the two-wire bus using a twisted pair, where the wires are wrapped around each other to provide shielding from unwanted electromagnetic induction, thus preventing interference with the relatively low voltage signals being carried through them. The twisted pairs have between 33 and 50 twists per meter. While the CAN bus is operating (active), one of the bus wires will carry a higher voltage and is referred to as the CAN High or CAN bus (+) wire, while the other bus wire will carry a lower voltage and is referred to as the CAN Low or CAN bus (-) wire. Refer to the CAN Bus Voltages table. All measurements taken between node ground and CAN terminal with a standard DVOM. DVOM will display average network voltage. Total resistance of CAN-C network can also be measured (60 ohms). Cannot measure total resistance of CAN-B network. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > System Information > Description and Operation > Description > Page 8588 In order to minimize the potential effects of Ignition-Off Draw (IOD), the CAN-B network employs a sleep strategy. However, a network sleep strategy should not be confused with the sleep strategy of the individual nodes on that network, as they may differ. For example: The CAN-C bus network is awake only when the ignition switch is in the ON or START positions; however, the TIPM, which is on the CAN-C bus, may still be awake with the ignition switch in the ACCESSORY or UNLOCK positions. The integrated circuitry of an individual node may be capable of processing certain sensor inputs and outputs without the need to utilize network resources. The CAN-B bus network remains active until all nodes on that network are ready for sleep. This is determined by the network using tokens in a manner similar to polling. When the last node that is active on the network is ready for sleep, and it has already received a token indicating that all other nodes on the bus are ready for sleep, it broadcasts a bus sleep acknowledgment message that causes the network to sleep. Once the CAN-B bus network is asleep, any node on the bus can awaken it by transmitting a message on the network. The TIPM will keep either the CAN-B or the CAN-C bus awake for a timed interval after it receives a diagnostic message for that bus over the Diagnostic CAN-C bus. In the CAN system, available options are configured into the TIPM at the assembly plant, but additional options can be added in the field using the diagnostic scan tool. The configuration settings are stored in non-volatile memory. The TIPM also has two 64-bit registers, which track each of the as-built and currently responding nodes on the CAN-B and CAN-C buses. The TIPM stores a Diagnostic Trouble Code (DTC) in one of two caches for any detected active or stored faults in the order in which they occur. One cache stores powertrain (P-Code), chassis (C-Code) and body (B-Code) DTCs, while the second cache is dedicated to storing network (U-Code) DTCs. If there are intermittent or active faults in the CAN network, a diagnostic scan tool connected to the Diagnostic CAN-C bus through the 16-way Data Link Connector (DLC) may only be able to communicate with the TIPM. To aid in CAN network diagnosis, the TIPM will provide CAN-B and CAN-C network status information to the scan tool using certain diagnostic signals. In addition, the transceiver in each node on the CAN-C bus will identify a bus off hardware failure, while the transceiver in each node on the CAN-B bus will identify a general bus hardware failure. The transceivers for some CAN-B nodes will also identify certain failures for both CAN-B bus signal wires. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Removal Front Bumper Cover / Fascia: Service and Repair Removal REMOVAL 1. Remove splash shield. Refer to Front Fender Liner. 2. Remove left and right side fastener (1) located in the wheel well. 3. Remove three fasteners (2) located at the bottom of fascia. 4. Remove middle fasteners (8) located on the top of the fascia. 5. If equipped, disconnect fog lamps (1). 6. Remove two fasteners located at the top of fascia (7). 7. Carefully, remove fascia from vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Removal > Page 8595 Front Bumper Cover / Fascia: Service and Repair Installation INSTALLATION 1. Lift fascia (2) and fasten both sides of fascia notch (3) onto push pin (6). 2. Install fasteners (1) located inside wheel well up through fascia. 3. Install fascia fasteners (7). 4. Install fascia fasteners (8) through fascia. 5. If equipped, connect wire harness (5) to fog lamp (4). 6. Raise vehicle. 7. Install push pins into locations (1). 8. Install fasteners (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Service and Repair > Removal Front Bumper Reinforcement: Service and Repair Removal REMOVAL 1. Remove fascia. 2. Disconnect wire connector (2) and remove horn (3). 3. Remove wire harness push pin fastener (1). 4. Remove wire harness (1) from bottom of bumper reinforcement. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Service and Repair > Removal > Page 8600 5. Remove 8 fasteners (2) from bumper reinforcement (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Service and Repair > Removal > Page 8601 Front Bumper Reinforcement: Service and Repair Installation INSTALLATION 1. Install fasteners (2) and torque to 23 Nm (204 in. lbs.). 2. Connect wire connector (2) and install horn (1). 3. Install wiring harness push pin. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Service and Repair > Removal > Page 8602 4. Install wire connector (1) to bumper reinforcement. 5. Install front fascia. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Removal Rear Bumper Cover / Fascia: Service and Repair Removal REMOVAL 1. Remove push pins (5) from holes (1) located on vehicle (2). 2. Remove rear splash shields. 3. Remove both left (7) and right screws (4). 4. Remove fascia from push pins (10). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Removal > Page 8608 Rear Bumper Cover / Fascia: Service and Repair Installation INSTALLATION 1. Raise fascia (6) and hang fascia onto push pins (10). 2. Install push pins (5) into push pin locations (1). 3. Install left (7) and right (4) screws into their respective locations. 4. Install splash shields. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System Information > Service and Repair > Removal Rear Bumper Reinforcement: Service and Repair Removal REMOVAL 1. Remove rear fascia. 2. Remove seven bumper reinforcement nuts (1). 3. Remove bumper reinforcement (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System Information > Service and Repair > Removal > Page 8613 Rear Bumper Reinforcement: Service and Repair Installation INSTALLATION 1. Place bumper reinforcement (2) up to frame locations. 2. Install seven nuts (1) and tighten to 23 Nm (204 in. lbs.) 3. Install fascia. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Cabin Ventilation Grille > Component Information > Service and Repair > Removal Cabin Ventilation Grille: Service and Repair Removal SCREEN-AIR INLET NOTE: LHD model shown. RHD model similar. 1. Remove the cowl grille screen. 2. Disengage the three push-in retainers (1) that secure the HVAC housing air inlet screen (2) to the cowl panel (3) and remove the screen. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Cabin Ventilation Grille > Component Information > Service and Repair > Removal > Page 8618 Cabin Ventilation Grille: Service and Repair Installation SCREEN-AIR INLET NOTE: LHD model shown. RHD model similar. 1. Position the HVAC housing air inlet screen (2) to the cowl panel (3) and fully engage the three push-in retainers (1) that secure the screen to the panel. 2. Install the cowl grille screen. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Removal Cowl Moulding / Trim: Service and Repair Removal REMOVAL 1. Remove the wiper arms (2). 2. Remove the hood seal (4). 3. Remove the screws (3) and remove the panel (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Removal > Page 8624 Cowl Moulding / Trim: Service and Repair Installation INSTALLATION 1. Position the end seals (1) into place. 2. Install the panel (2) and install the screws (3). 3. Install the hood seal (4). 4. Install the wiper arms (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair > Removal Front Door Exterior Handle: Service and Repair Removal REMOVAL 1. Remove bolster. 2. Remove door plugs. 3. Remove door module. 4. Raise window to up position. 5. Remove key cylinder lock link rod (5) from lock cylinder (1). 6. Remove handle link rod (4) from handle (2). 7. Remove screws (6) from handle assembly (2). 8. Remove handle assembly (2) from door (3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair > Removal > Page 8633 Front Door Exterior Handle: Service and Repair Installation INSTALLATION 1. Raise window to up position. 2. Insert lock cylinder (1) into door handle (2) then into door opening. 3. Tighten screws (6) to 8 Nm (6 ft. lbs.) 4. Connect lock cylinder link rod (5) on to lock cylinder (1). 5. Connect handle link rod (4) on to door handle (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair > Removal Front Door Interior Handle: Service and Repair Removal REMOVAL 1. Unsnap link rod to latch (1). 2. Remove screw (3) attaching plate to panel. 3. Unsnap housing snaps from (2) belt line ribs on trim panel. 4. Pull up on trim panel belt line to aid in unsnapping of housing. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair > Removal > Page 8638 Front Door Interior Handle: Service and Repair Installation INSTALLATION 1. Snap inside handle to belt line ribs (2) on trim panel. 2. Install screw (3) attaching handle to panel. 3. Snap link rod to latch. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > Customer Interest for Front Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises Front Door Hinge: Customer Interest Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > Customer Interest for Front Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 8647 This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > Customer Interest for Front Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 8648 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises Front Door Hinge: All Technical Service Bulletins Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 8654 This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 8655 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > Page 8656 Front Door Hinge: By Symptom Technical Service Bulletin # 23-018-10 Date: 101021 Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > Page 8657 SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > Page 8658 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 23-018-10 Date: 101021 Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > Page 8659 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > Page 8660 CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair > Removal Front Door Hinge: Service and Repair Removal REMOVAL 1. Remove nuts (3) from door studs (1). 2. Remove door. 3. Disconnect door harness (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair > Removal > Page 8663 Front Door Hinge: Service and Repair Installation INSTALLATION 1. Connect door harness (2). 2. Install door studs (1) into door hinges. 3. Install nuts (3) onto door studs. Tighten to 26 Nm (19 ft. lbs.) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Adjustments Front Door Latch: Adjustments FRONT DOOR LATCH ADJUSTMENT 1. Insert a Torx(R)-wrench through the elongated hole in the door end frame near the latch striker opening. 2. Loosen Torx(R) head screw on the side of the latch linkage. 3. Push button on outside door handle and release it. 4. Tighten Torx(R) head screw on latch. 5. Verify latch operation. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Removal Front Door Latch: Service and Repair Removal REMOVAL 1. If equipped, disconnect wire harness from Latch. 2. Disconnect inside hand link (5) and lock rod (6) from latch (4). 3. Unscrew latch presenter or unsnap latch from presenter. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Removal > Page 8669 Front Door Latch: Service and Repair Installation INSTALLATION 1. Move glass to the full up position. 2. Install latch assembly into door face (1). 3. Connect hand link (5) and lock rod (6) into latch. 4. Install fasteners and torque to 9 Nm (7 ft. lbs.) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest for Front Door Panel: > 23-009-07 > Mar > 07 > Interior Buzz/Rattle From Front/Rear Door panels Front Door Panel: Customer Interest Interior - Buzz/Rattle From Front/Rear Door panels NUMBER: 23-009-07 GROUP: Body DATE: March 20, 2007 SUBJECT: Radio Speaker Misdiagnosis - Rattle/Buzz Sounds in Door Modules OVERVIEW: This bulletin involves removing the Bolster and Door Panel Modules and applying foam tape at critical points of wiring, actuator rods, panel connection points and the side Instrument Panel end caps. PARTS REQUIRED: MODELS: 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber SYMPTOM/CONDITION: Rattle or Buzz like sounds in the door module area, (front or rear). This is most noticeable with the radio on during high volume/deep base settings and is most likely caused by door links or wiring vibrating in the door module. The door module rattle or buzz sounds will not be heard with the radio off. Several areas of concern are involved and if the vehicle operator complains of rattles or buzz noises, perform the following Repair Procedure on ALL doors and both ends of Instrument Panel before replacing speakers. DIAGNOSIS: If the symptom/condition is present, perform the Repair Procedure. FRONT DOOR REPAIR PROCEDURE: 1. Lower the front windows: a. MK: 89 mm (3.5 in.) b. PM: 102 mm (4 in.) 2.5GLower the rear windows 152 mm (6 in.), (Preparing for rear door Repair Procedure). 3. Disconnect and isolate negative battery cable. 4. Pull weatherstrip off front of door at wire harness door bracket entering door. Remove 2 bolts, (5 mm hex), at retaining plate. Disconnect wire harness from body of vehicle. Pull wiring from behind weatherstrip. 5. Remove trim cap and screw, (T-20 Torx), at inside door handle. 6. Remove manual window crank handle, (if equipped). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest for Front Door Panel: > 23-009-07 > Mar > 07 > Interior Buzz/Rattle From Front/Rear Door panels > Page 8678 7. Remove interior trim flag for outside mirror, disconnect wire harness to electric mirror, (if equipped). 8. Using trim stick, remove speaker cover. 9. Remove top front and lower rear speaker screws only, (T-20 Torx). (Speaker will stay with door module). 10. Remove bolt(s), (10 mm hex), retaining door module near speaker: a. MK: 2 bolts. b. PM: 1 bolt. 11. Remove (2) longer bolts, (10 mm hex), retaining door module at bottom of door module. 12. Remove trim cap and screw, (T-20 Torx), at inside door pull cup. 13. Using trim stick, release bolster, swing down and allow to hang by tethers. 14. Release both window latches on regulator, pull up and roll back of window up to remove from door from the outside of door. Set glass aside on protected surface. 15. Remove bolts, (10 mm hex), behind bolster, (2 in regulators and 1 at center of door module). 16. Disconnect linkages at door latch to: a. Outside door handle, (both sides of vehicle). b. Lock cylinder, (drivers side only). 17. Remove (3) screws, (T-30 Torx), retaining latch to door. 18. Maneuver door module up, then forward, then down to remove from door. 19. Place removed door module face down on a clean, protected surface. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest for Front Door Panel: > 23-009-07 > Mar > 07 > Interior Buzz/Rattle From Front/Rear Door panels > Page 8679 20. Remove wiring and convolute tubing from retainers and wrap with Open Cell Foam Tape, (p/n 05019057AA), in the areas described in below. Any wiring or convoluted tubing that is not wrapped or can come in contact with the door module shell should be wrapped with foam tape as shown in (Fig. 1) for MK and (Fig. 2) for PM. Reinstall wiring and convolute tubing in retainers. 21. Follow specific instructions based on vehicle below: a. MK: Cut the Closed Cell Low Density Foam Tape, (p/n 05019058AA) into 25 mm (1 in.) lengths and stack, (if needed), to back up actuator rods as shown in (Fig. 1), above. Place a piece of Itch and Squeak Tape, (p/n 05019054AA) on the top layer of Closed Cell Low Density Foam Tape where it contacts actuator rod. b. PM: Cut the Closed Cell Low Density Foam Tape, (p/n 05019058AA) into 12 mm (.5 in.) length to back up actuator rod as shown in (Fig. 3) below. NOTE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest for Front Door Panel: > 23-009-07 > Mar > 07 > Interior Buzz/Rattle From Front/Rear Door panels > Page 8680 Actuator rod is removed and pulled from stay for easy installation 22. Turn door module over, (face up) and cut 6 lengths of Open Cell Foam Tape, (p/n 05019057AA) into 6.5 mm (.25 in.) strips lengthwise. Install on door bolster TOP and BOTTOM horizontal surfaces on the smooth surface where it meets door module opening. Start at the forward most section of the bolster to the rear most area of the horizontal surface isolating the Bolster from the mating surface of the door Panel Module. See (Fig. 4) below. Bottom of Bolster is shown, Top is similar. 23. Loosely install the lower bolt(s), (10 mm hex), for window regulator in bottom of door module. Thread bolt(s) into door module so that threads protrude through module about 12 mm, (.5 in.) then start threads into bottom of regulator. Bolt should now be threaded into door module and regulator with a space in between regulator and door module. Be sure window regulator guide tab is in proper position in door module. 24. Position door module in door shell making sure to slip wiring to body, (at front of door), behind weather-strip and guide window regulators and door latch mechanisms in place inside door shell. 25. Align top of door module in position and slide down in place. Lower window regulator bolts installed earlier in step Step # 23 should slide in "V" notch(s) in bottom of door with regulators inside door shell. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest for Front Door Panel: > 23-009-07 > Mar > 07 > Interior Buzz/Rattle From Front/Rear Door panels > Page 8681 NOTE: Be sure mirror wiring protrudes through opening in top of door module. 26. Start, (do not tighten), all remaining bolts for door module and window regulators. Once all bolts are loosely installed, tighten all bolts to 8 N.m (71 in. lbs.) 27. Install door latch screws, (T-30 Torx), Tighten to 7 N.m (62 in. lbs.). 28. Connect linkage(s) to door latch mechanism. 29. Position wire harness door bracket at front of door and install screws, (5 mm hex). Install weatherstrip. 30. Connect wire harness to body from door. 31. Connect mirror wire harness, (if equipped) and install trim flag. 32. Install screw, (T-20 Torx), at inner door handle and replace trim. 33. Install door glass making sure glass clips into regulator securely. 34. Install door bolster trim panel. 35. Install screw, (T-20 Torx), and trim cap at door pull cup. 36. Install manual window crank handle, (if equipped). 37. Install speaker screws, (T-20 Torx), and speaker grille. 38. Clean glass. 39. Repeat this process for other front door. REAR DOOR REPAIR PROCEDURE: 1. Pull weatherstrip off front of door at wire harness bracket entering door. Remove 2 bolts, (5 mm hex) at wire harness door bracket. Disconnect wire harness from body of vehicle. 2. Remove trim cap and screw, (T-20 Torx), at inside door handle. 3. Remove manual window crank handle, (if equipped). 4. Using trim stick, remove speaker cover. 5. Remove top front and lower rear speaker screws only. (Speaker will remain with door module). 6. Remove bolt(s), (10 mm hex), retaining door module near speaker. a. MK: 2 bolts b. PM: 1 bolt 7. Remove (1) longer bolt, (10 mm hex), retaining door module and window regulator at bottom of door module. 8. Remove trim cap and screw, (1-20 Torx), at inside door pull cup. 9. Using trim stick, release bolster, swing down and allow to hang by tethers. 10. Release window latch retainer at bottom of glass from regulator. 11. Slide glass up in frame and duct tape from outside of window, up over frame to inside of window in the full UP position. 12. Remove bolts, (10 mm hex) behind bolster: a. MK: 2 in regulator and 1 at center of door module. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest for Front Door Panel: > 23-009-07 > Mar > 07 > Interior Buzz/Rattle From Front/Rear Door panels > Page 8682 b. PM: 1 in regulator, 2 in window motor brace and 1 in door module. 13. Disconnect linkage(s) at latch to: a. MK49 - Compass 1). Outside door handle and 2). Fulcrum. b. MK74 - Patriot and PM - Caliber Outside door handle. 14. Remove (3) screws, (T-30 Torx), retaining latch to door. 15. Maneuver door module up, then forward, then down to remove from door. 16. Place removed door module face down on a clean, protected surface. 17. Follow specific instructions based on vehicle below: a. MK: Remove wiring and convolute tubing from retainers and wrap with Open Cell Foam Tape, (p/n 05019057AA) in the areas described in below. Any wiring or convoluted tubing that is not wrapped or can come in contact with the door module shell should be wrapped with foam tape as shown in (Fig. 6) below. Reinstall wiring and convolute tubing back in retainers. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest for Front Door Panel: > 23-009-07 > Mar > 07 > Interior Buzz/Rattle From Front/Rear Door panels > Page 8683 b. PM: Remove wiring and convolute tubing from retainers and wrap with Open Cell Foam Tape, (p/n 05019057AA) in the areas described in below. Any wiring or convoluted tubing that is not wrapped or can come in contact with the door module shell should be wrapped with foam tape as shown in (Fig. 7) below. Reinstall wiring and convolute tubing back in retainers. 18. Cut the Closed Cell Low Density Foam Tape, (p/n 05019058AA) into 1" lengths and stack (if needed) to back up actuator rods with Itch and Squeak Tape, (p/n 05019054AA) as top layer, as shown in (Fig. 8) below. NOTE: If # 2 below is not existing, install it. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest for Front Door Panel: > 23-009-07 > Mar > 07 > Interior Buzz/Rattle From Front/Rear Door panels > Page 8684 19. Follow specific instructions based on vehicle below: a. MK: cut 12 mm (.5 in) Open Cell Foam Tape, (p/n 05019057AA) and put at top rear corner of door module as shown in (Fig. 9) below. Do not allow Foam Tape to protrude past outside edge of door module. b. PM: cut 1.5 in Closed Cell Low Density Foam Tape, (p/n 05019058AA) and put at top rear corner of door module, inside outer lip as shown in (Fig. 10) below. Do not allow Foam Tape to protrude past outside edge of door module. 20. Turn door module over, (face up) and cut 6 lengths of Open Cell Foam Tape, (p/n 05019057AA) into 6.5 mm (.25 in.) strips lengthwise. Install on door bolster TOP and BOTTOM horizontal surfaces on the smooth surface where it meets door module opening. Start at the forward most section of the bolster to the rear most area of the horizontal surface isolating the Bolster from the mating surface of the door Panel Module. See (Fig. 4) above for front door. 21. Loosely install the longer bolt, (10 mm hex), for window regulator in bottom of door module. Thread bolt into door module so that threads protrude through module about 9.5 mm, (.375 in) then start threads into bottom of regulator. Bolt should now be threaded into door module and regulator with a space in between regulator and door module, similar to (Fig. 5) above. Be sure window regulator guide tab is in proper position in door module. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest for Front Door Panel: > 23-009-07 > Mar > 07 > Interior Buzz/Rattle From Front/Rear Door panels > Page 8685 22. Position door module in door shell making sure to slip wiring to body, (at front of door), behind weatherstrip and guide window regulator and door latch mechanisms in place inside door shell. 23. Align top of door module in position and slide down in place. Lower window regulator bolt installed earlier in step Step # 21 should slide in "V" notch in bottom of door with regulator inside door shell. 24. Start, (do not tighten), all remaining bolts, (10 mm hex), for door module and window regulator. Tighten all bolts to 8 N.m (71 in. lbs.) 25. Install door latch screws, (T-30 Torx), Tighten to 7 N.m (62 in. lbs.). 26. Connect linkage(s) to door latch mechanism. 27. Position wire harness door bracket at front of door and install screws, (5 mm hex). Install weatherstrip. 28. Connect wire harness to body from door. 29. Install screw, (T-20 Torx), at inner door handle and replace trim. 30. Remove previously installed tape from door glass and slide door glass down making sure glass clips into regulator securely. 31. Install door bolster trim panel. 32. Install screw, (T-20 Torx), and trim cap at door pull cup. 33. Install manual window crank handle, (if equipped). 34. Install speaker screws and speaker grille. 35. Clean glass. 36. Repeat this process for other rear door. INSTRUMENT PANEL END CAP REPAIR PROCEDURE: 1. Loosen weatherstrip along front edge of instrument panel end cap. 2. Remove instrument panel end cap. 3. Cut 8 (.5 in.) pieces, (4 for each side) of Open Cell Foam Tape, (p/n 05019057AA). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest for Front Door Panel: > 23-009-07 > Mar > 07 > Interior Buzz/Rattle From Front/Rear Door panels > Page 8686 4. Install 4 pieces of Open Cell Foam Tape at the mating surface for the cover as shown in # 1 (Fig. 11) below. 5. Cut 6 square pieces, (3 for each side) of Closed Cell Low Density Foam Tape, (p/n 05019058AA). 6. Stack 3 pieces of Closed Cell Low Density Foam Tape and cover top layer with Itch and Squeak Tape, (pin 05019054AA). Adhere stack towards the center area of cover on the end of the instrument panel as shown in #2 (Fig. 11) below. 7. Replace instrument panel end cover and reposition weatherstrip. 8. Repeat steps (1) through (7) for other side of instrument panel. 9. Reconnect battery negative cable. 10. Check operation of all door related systems, and audio functions. 11. Reset clock for customer satisfaction. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 23-009-07 > Mar > 07 > Interior - Buzz/Rattle From Front/Rear Door panels Front Door Panel: All Technical Service Bulletins Interior - Buzz/Rattle From Front/Rear Door panels NUMBER: 23-009-07 GROUP: Body DATE: March 20, 2007 SUBJECT: Radio Speaker Misdiagnosis - Rattle/Buzz Sounds in Door Modules OVERVIEW: This bulletin involves removing the Bolster and Door Panel Modules and applying foam tape at critical points of wiring, actuator rods, panel connection points and the side Instrument Panel end caps. PARTS REQUIRED: MODELS: 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber SYMPTOM/CONDITION: Rattle or Buzz like sounds in the door module area, (front or rear). This is most noticeable with the radio on during high volume/deep base settings and is most likely caused by door links or wiring vibrating in the door module. The door module rattle or buzz sounds will not be heard with the radio off. Several areas of concern are involved and if the vehicle operator complains of rattles or buzz noises, perform the following Repair Procedure on ALL doors and both ends of Instrument Panel before replacing speakers. DIAGNOSIS: If the symptom/condition is present, perform the Repair Procedure. FRONT DOOR REPAIR PROCEDURE: 1. Lower the front windows: a. MK: 89 mm (3.5 in.) b. PM: 102 mm (4 in.) 2.5GLower the rear windows 152 mm (6 in.), (Preparing for rear door Repair Procedure). 3. Disconnect and isolate negative battery cable. 4. Pull weatherstrip off front of door at wire harness door bracket entering door. Remove 2 bolts, (5 mm hex), at retaining plate. Disconnect wire harness from body of vehicle. Pull wiring from behind weatherstrip. 5. Remove trim cap and screw, (T-20 Torx), at inside door handle. 6. Remove manual window crank handle, (if equipped). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 23-009-07 > Mar > 07 > Interior - Buzz/Rattle From Front/Rear Door panels > Page 8692 7. Remove interior trim flag for outside mirror, disconnect wire harness to electric mirror, (if equipped). 8. Using trim stick, remove speaker cover. 9. Remove top front and lower rear speaker screws only, (T-20 Torx). (Speaker will stay with door module). 10. Remove bolt(s), (10 mm hex), retaining door module near speaker: a. MK: 2 bolts. b. PM: 1 bolt. 11. Remove (2) longer bolts, (10 mm hex), retaining door module at bottom of door module. 12. Remove trim cap and screw, (T-20 Torx), at inside door pull cup. 13. Using trim stick, release bolster, swing down and allow to hang by tethers. 14. Release both window latches on regulator, pull up and roll back of window up to remove from door from the outside of door. Set glass aside on protected surface. 15. Remove bolts, (10 mm hex), behind bolster, (2 in regulators and 1 at center of door module). 16. Disconnect linkages at door latch to: a. Outside door handle, (both sides of vehicle). b. Lock cylinder, (drivers side only). 17. Remove (3) screws, (T-30 Torx), retaining latch to door. 18. Maneuver door module up, then forward, then down to remove from door. 19. Place removed door module face down on a clean, protected surface. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 23-009-07 > Mar > 07 > Interior - Buzz/Rattle From Front/Rear Door panels > Page 8693 20. Remove wiring and convolute tubing from retainers and wrap with Open Cell Foam Tape, (p/n 05019057AA), in the areas described in below. Any wiring or convoluted tubing that is not wrapped or can come in contact with the door module shell should be wrapped with foam tape as shown in (Fig. 1) for MK and (Fig. 2) for PM. Reinstall wiring and convolute tubing in retainers. 21. Follow specific instructions based on vehicle below: a. MK: Cut the Closed Cell Low Density Foam Tape, (p/n 05019058AA) into 25 mm (1 in.) lengths and stack, (if needed), to back up actuator rods as shown in (Fig. 1), above. Place a piece of Itch and Squeak Tape, (p/n 05019054AA) on the top layer of Closed Cell Low Density Foam Tape where it contacts actuator rod. b. PM: Cut the Closed Cell Low Density Foam Tape, (p/n 05019058AA) into 12 mm (.5 in.) length to back up actuator rod as shown in (Fig. 3) below. NOTE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 23-009-07 > Mar > 07 > Interior - Buzz/Rattle From Front/Rear Door panels > Page 8694 Actuator rod is removed and pulled from stay for easy installation 22. Turn door module over, (face up) and cut 6 lengths of Open Cell Foam Tape, (p/n 05019057AA) into 6.5 mm (.25 in.) strips lengthwise. Install on door bolster TOP and BOTTOM horizontal surfaces on the smooth surface where it meets door module opening. Start at the forward most section of the bolster to the rear most area of the horizontal surface isolating the Bolster from the mating surface of the door Panel Module. See (Fig. 4) below. Bottom of Bolster is shown, Top is similar. 23. Loosely install the lower bolt(s), (10 mm hex), for window regulator in bottom of door module. Thread bolt(s) into door module so that threads protrude through module about 12 mm, (.5 in.) then start threads into bottom of regulator. Bolt should now be threaded into door module and regulator with a space in between regulator and door module. Be sure window regulator guide tab is in proper position in door module. 24. Position door module in door shell making sure to slip wiring to body, (at front of door), behind weather-strip and guide window regulators and door latch mechanisms in place inside door shell. 25. Align top of door module in position and slide down in place. Lower window regulator bolts installed earlier in step Step # 23 should slide in "V" notch(s) in bottom of door with regulators inside door shell. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 23-009-07 > Mar > 07 > Interior - Buzz/Rattle From Front/Rear Door panels > Page 8695 NOTE: Be sure mirror wiring protrudes through opening in top of door module. 26. Start, (do not tighten), all remaining bolts for door module and window regulators. Once all bolts are loosely installed, tighten all bolts to 8 N.m (71 in. lbs.) 27. Install door latch screws, (T-30 Torx), Tighten to 7 N.m (62 in. lbs.). 28. Connect linkage(s) to door latch mechanism. 29. Position wire harness door bracket at front of door and install screws, (5 mm hex). Install weatherstrip. 30. Connect wire harness to body from door. 31. Connect mirror wire harness, (if equipped) and install trim flag. 32. Install screw, (T-20 Torx), at inner door handle and replace trim. 33. Install door glass making sure glass clips into regulator securely. 34. Install door bolster trim panel. 35. Install screw, (T-20 Torx), and trim cap at door pull cup. 36. Install manual window crank handle, (if equipped). 37. Install speaker screws, (T-20 Torx), and speaker grille. 38. Clean glass. 39. Repeat this process for other front door. REAR DOOR REPAIR PROCEDURE: 1. Pull weatherstrip off front of door at wire harness bracket entering door. Remove 2 bolts, (5 mm hex) at wire harness door bracket. Disconnect wire harness from body of vehicle. 2. Remove trim cap and screw, (T-20 Torx), at inside door handle. 3. Remove manual window crank handle, (if equipped). 4. Using trim stick, remove speaker cover. 5. Remove top front and lower rear speaker screws only. (Speaker will remain with door module). 6. Remove bolt(s), (10 mm hex), retaining door module near speaker. a. MK: 2 bolts b. PM: 1 bolt 7. Remove (1) longer bolt, (10 mm hex), retaining door module and window regulator at bottom of door module. 8. Remove trim cap and screw, (1-20 Torx), at inside door pull cup. 9. Using trim stick, release bolster, swing down and allow to hang by tethers. 10. Release window latch retainer at bottom of glass from regulator. 11. Slide glass up in frame and duct tape from outside of window, up over frame to inside of window in the full UP position. 12. Remove bolts, (10 mm hex) behind bolster: a. MK: 2 in regulator and 1 at center of door module. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 23-009-07 > Mar > 07 > Interior - Buzz/Rattle From Front/Rear Door panels > Page 8696 b. PM: 1 in regulator, 2 in window motor brace and 1 in door module. 13. Disconnect linkage(s) at latch to: a. MK49 - Compass 1). Outside door handle and 2). Fulcrum. b. MK74 - Patriot and PM - Caliber Outside door handle. 14. Remove (3) screws, (T-30 Torx), retaining latch to door. 15. Maneuver door module up, then forward, then down to remove from door. 16. Place removed door module face down on a clean, protected surface. 17. Follow specific instructions based on vehicle below: a. MK: Remove wiring and convolute tubing from retainers and wrap with Open Cell Foam Tape, (p/n 05019057AA) in the areas described in below. Any wiring or convoluted tubing that is not wrapped or can come in contact with the door module shell should be wrapped with foam tape as shown in (Fig. 6) below. Reinstall wiring and convolute tubing back in retainers. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 23-009-07 > Mar > 07 > Interior - Buzz/Rattle From Front/Rear Door panels > Page 8697 b. PM: Remove wiring and convolute tubing from retainers and wrap with Open Cell Foam Tape, (p/n 05019057AA) in the areas described in below. Any wiring or convoluted tubing that is not wrapped or can come in contact with the door module shell should be wrapped with foam tape as shown in (Fig. 7) below. Reinstall wiring and convolute tubing back in retainers. 18. Cut the Closed Cell Low Density Foam Tape, (p/n 05019058AA) into 1" lengths and stack (if needed) to back up actuator rods with Itch and Squeak Tape, (p/n 05019054AA) as top layer, as shown in (Fig. 8) below. NOTE: If # 2 below is not existing, install it. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 23-009-07 > Mar > 07 > Interior - Buzz/Rattle From Front/Rear Door panels > Page 8698 19. Follow specific instructions based on vehicle below: a. MK: cut 12 mm (.5 in) Open Cell Foam Tape, (p/n 05019057AA) and put at top rear corner of door module as shown in (Fig. 9) below. Do not allow Foam Tape to protrude past outside edge of door module. b. PM: cut 1.5 in Closed Cell Low Density Foam Tape, (p/n 05019058AA) and put at top rear corner of door module, inside outer lip as shown in (Fig. 10) below. Do not allow Foam Tape to protrude past outside edge of door module. 20. Turn door module over, (face up) and cut 6 lengths of Open Cell Foam Tape, (p/n 05019057AA) into 6.5 mm (.25 in.) strips lengthwise. Install on door bolster TOP and BOTTOM horizontal surfaces on the smooth surface where it meets door module opening. Start at the forward most section of the bolster to the rear most area of the horizontal surface isolating the Bolster from the mating surface of the door Panel Module. See (Fig. 4) above for front door. 21. Loosely install the longer bolt, (10 mm hex), for window regulator in bottom of door module. Thread bolt into door module so that threads protrude through module about 9.5 mm, (.375 in) then start threads into bottom of regulator. Bolt should now be threaded into door module and regulator with a space in between regulator and door module, similar to (Fig. 5) above. Be sure window regulator guide tab is in proper position in door module. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 23-009-07 > Mar > 07 > Interior - Buzz/Rattle From Front/Rear Door panels > Page 8699 22. Position door module in door shell making sure to slip wiring to body, (at front of door), behind weatherstrip and guide window regulator and door latch mechanisms in place inside door shell. 23. Align top of door module in position and slide down in place. Lower window regulator bolt installed earlier in step Step # 21 should slide in "V" notch in bottom of door with regulator inside door shell. 24. Start, (do not tighten), all remaining bolts, (10 mm hex), for door module and window regulator. Tighten all bolts to 8 N.m (71 in. lbs.) 25. Install door latch screws, (T-30 Torx), Tighten to 7 N.m (62 in. lbs.). 26. Connect linkage(s) to door latch mechanism. 27. Position wire harness door bracket at front of door and install screws, (5 mm hex). Install weatherstrip. 28. Connect wire harness to body from door. 29. Install screw, (T-20 Torx), at inner door handle and replace trim. 30. Remove previously installed tape from door glass and slide door glass down making sure glass clips into regulator securely. 31. Install door bolster trim panel. 32. Install screw, (T-20 Torx), and trim cap at door pull cup. 33. Install manual window crank handle, (if equipped). 34. Install speaker screws and speaker grille. 35. Clean glass. 36. Repeat this process for other rear door. INSTRUMENT PANEL END CAP REPAIR PROCEDURE: 1. Loosen weatherstrip along front edge of instrument panel end cap. 2. Remove instrument panel end cap. 3. Cut 8 (.5 in.) pieces, (4 for each side) of Open Cell Foam Tape, (p/n 05019057AA). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 23-009-07 > Mar > 07 > Interior - Buzz/Rattle From Front/Rear Door panels > Page 8700 4. Install 4 pieces of Open Cell Foam Tape at the mating surface for the cover as shown in # 1 (Fig. 11) below. 5. Cut 6 square pieces, (3 for each side) of Closed Cell Low Density Foam Tape, (p/n 05019058AA). 6. Stack 3 pieces of Closed Cell Low Density Foam Tape and cover top layer with Itch and Squeak Tape, (pin 05019054AA). Adhere stack towards the center area of cover on the end of the instrument panel as shown in #2 (Fig. 11) below. 7. Replace instrument panel end cover and reposition weatherstrip. 8. Repeat steps (1) through (7) for other side of instrument panel. 9. Reconnect battery negative cable. 10. Check operation of all door related systems, and audio functions. 11. Reset clock for customer satisfaction. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 8701 Front Door Panel: By Symptom Technical Service Bulletin # 23-009-07 Date: 070320 Interior - Buzz/Rattle From Front/Rear Door panels NUMBER: 23-009-07 GROUP: Body DATE: March 20, 2007 SUBJECT: Radio Speaker Misdiagnosis - Rattle/Buzz Sounds in Door Modules OVERVIEW: This bulletin involves removing the Bolster and Door Panel Modules and applying foam tape at critical points of wiring, actuator rods, panel connection points and the side Instrument Panel end caps. PARTS REQUIRED: MODELS: 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber SYMPTOM/CONDITION: Rattle or Buzz like sounds in the door module area, (front or rear). This is most noticeable with the radio on during high volume/deep base settings and is most likely caused by door links or wiring vibrating in the door module. The door module rattle or buzz sounds will not be heard with the radio off. Several areas of concern are involved and if the vehicle operator complains of rattles or buzz noises, perform the following Repair Procedure on ALL doors and both ends of Instrument Panel before replacing speakers. DIAGNOSIS: If the symptom/condition is present, perform the Repair Procedure. FRONT DOOR REPAIR PROCEDURE: 1. Lower the front windows: a. MK: 89 mm (3.5 in.) b. PM: 102 mm (4 in.) 2.5GLower the rear windows 152 mm (6 in.), (Preparing for rear door Repair Procedure). 3. Disconnect and isolate negative battery cable. 4. Pull weatherstrip off front of door at wire harness door bracket entering door. Remove 2 bolts, (5 mm hex), at retaining plate. Disconnect wire harness from body of vehicle. Pull wiring from behind weatherstrip. 5. Remove trim cap and screw, (T-20 Torx), at inside door handle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 8702 6. Remove manual window crank handle, (if equipped). 7. Remove interior trim flag for outside mirror, disconnect wire harness to electric mirror, (if equipped). 8. Using trim stick, remove speaker cover. 9. Remove top front and lower rear speaker screws only, (T-20 Torx). (Speaker will stay with door module). 10. Remove bolt(s), (10 mm hex), retaining door module near speaker: a. MK: 2 bolts. b. PM: 1 bolt. 11. Remove (2) longer bolts, (10 mm hex), retaining door module at bottom of door module. 12. Remove trim cap and screw, (T-20 Torx), at inside door pull cup. 13. Using trim stick, release bolster, swing down and allow to hang by tethers. 14. Release both window latches on regulator, pull up and roll back of window up to remove from door from the outside of door. Set glass aside on protected surface. 15. Remove bolts, (10 mm hex), behind bolster, (2 in regulators and 1 at center of door module). 16. Disconnect linkages at door latch to: a. Outside door handle, (both sides of vehicle). b. Lock cylinder, (drivers side only). 17. Remove (3) screws, (T-30 Torx), retaining latch to door. 18. Maneuver door module up, then forward, then down to remove from door. 19. Place removed door module face down on a clean, protected surface. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 8703 20. Remove wiring and convolute tubing from retainers and wrap with Open Cell Foam Tape, (p/n 05019057AA), in the areas described in below. Any wiring or convoluted tubing that is not wrapped or can come in contact with the door module shell should be wrapped with foam tape as shown in (Fig. 1) for MK and (Fig. 2) for PM. Reinstall wiring and convolute tubing in retainers. 21. Follow specific instructions based on vehicle below: a. MK: Cut the Closed Cell Low Density Foam Tape, (p/n 05019058AA) into 25 mm (1 in.) lengths and stack, (if needed), to back up actuator rods as shown in (Fig. 1), above. Place a piece of Itch and Squeak Tape, (p/n 05019054AA) on the top layer of Closed Cell Low Density Foam Tape where it contacts actuator rod. b. PM: Cut the Closed Cell Low Density Foam Tape, (p/n 05019058AA) into 12 mm (.5 in.) length to back up actuator rod as shown in (Fig. 3) below. NOTE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 8704 Actuator rod is removed and pulled from stay for easy installation 22. Turn door module over, (face up) and cut 6 lengths of Open Cell Foam Tape, (p/n 05019057AA) into 6.5 mm (.25 in.) strips lengthwise. Install on door bolster TOP and BOTTOM horizontal surfaces on the smooth surface where it meets door module opening. Start at the forward most section of the bolster to the rear most area of the horizontal surface isolating the Bolster from the mating surface of the door Panel Module. See (Fig. 4) below. Bottom of Bolster is shown, Top is similar. 23. Loosely install the lower bolt(s), (10 mm hex), for window regulator in bottom of door module. Thread bolt(s) into door module so that threads protrude through module about 12 mm, (.5 in.) then start threads into bottom of regulator. Bolt should now be threaded into door module and regulator with a space in between regulator and door module. Be sure window regulator guide tab is in proper position in door module. 24. Position door module in door shell making sure to slip wiring to body, (at front of door), behind weather-strip and guide window regulators and door latch mechanisms in place inside door shell. 25. Align top of door module in position and slide down in place. Lower window regulator bolts installed earlier in step Step # 23 should slide in "V" notch(s) in bottom of door with regulators inside door shell. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 8705 NOTE: Be sure mirror wiring protrudes through opening in top of door module. 26. Start, (do not tighten), all remaining bolts for door module and window regulators. Once all bolts are loosely installed, tighten all bolts to 8 N.m (71 in. lbs.) 27. Install door latch screws, (T-30 Torx), Tighten to 7 N.m (62 in. lbs.). 28. Connect linkage(s) to door latch mechanism. 29. Position wire harness door bracket at front of door and install screws, (5 mm hex). Install weatherstrip. 30. Connect wire harness to body from door. 31. Connect mirror wire harness, (if equipped) and install trim flag. 32. Install screw, (T-20 Torx), at inner door handle and replace trim. 33. Install door glass making sure glass clips into regulator securely. 34. Install door bolster trim panel. 35. Install screw, (T-20 Torx), and trim cap at door pull cup. 36. Install manual window crank handle, (if equipped). 37. Install speaker screws, (T-20 Torx), and speaker grille. 38. Clean glass. 39. Repeat this process for other front door. REAR DOOR REPAIR PROCEDURE: 1. Pull weatherstrip off front of door at wire harness bracket entering door. Remove 2 bolts, (5 mm hex) at wire harness door bracket. Disconnect wire harness from body of vehicle. 2. Remove trim cap and screw, (T-20 Torx), at inside door handle. 3. Remove manual window crank handle, (if equipped). 4. Using trim stick, remove speaker cover. 5. Remove top front and lower rear speaker screws only. (Speaker will remain with door module). 6. Remove bolt(s), (10 mm hex), retaining door module near speaker. a. MK: 2 bolts b. PM: 1 bolt 7. Remove (1) longer bolt, (10 mm hex), retaining door module and window regulator at bottom of door module. 8. Remove trim cap and screw, (1-20 Torx), at inside door pull cup. 9. Using trim stick, release bolster, swing down and allow to hang by tethers. 10. Release window latch retainer at bottom of glass from regulator. 11. Slide glass up in frame and duct tape from outside of window, up over frame to inside of window in the full UP position. 12. Remove bolts, (10 mm hex) behind bolster: a. MK: 2 in regulator and 1 at center of door module. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 8706 b. PM: 1 in regulator, 2 in window motor brace and 1 in door module. 13. Disconnect linkage(s) at latch to: a. MK49 - Compass 1). Outside door handle and 2). Fulcrum. b. MK74 - Patriot and PM - Caliber Outside door handle. 14. Remove (3) screws, (T-30 Torx), retaining latch to door. 15. Maneuver door module up, then forward, then down to remove from door. 16. Place removed door module face down on a clean, protected surface. 17. Follow specific instructions based on vehicle below: a. MK: Remove wiring and convolute tubing from retainers and wrap with Open Cell Foam Tape, (p/n 05019057AA) in the areas described in below. Any wiring or convoluted tubing that is not wrapped or can come in contact with the door module shell should be wrapped with foam tape as shown in (Fig. 6) below. Reinstall wiring and convolute tubing back in retainers. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 8707 b. PM: Remove wiring and convolute tubing from retainers and wrap with Open Cell Foam Tape, (p/n 05019057AA) in the areas described in below. Any wiring or convoluted tubing that is not wrapped or can come in contact with the door module shell should be wrapped with foam tape as shown in (Fig. 7) below. Reinstall wiring and convolute tubing back in retainers. 18. Cut the Closed Cell Low Density Foam Tape, (p/n 05019058AA) into 1" lengths and stack (if needed) to back up actuator rods with Itch and Squeak Tape, (p/n 05019054AA) as top layer, as shown in (Fig. 8) below. NOTE: If # 2 below is not existing, install it. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 8708 19. Follow specific instructions based on vehicle below: a. MK: cut 12 mm (.5 in) Open Cell Foam Tape, (p/n 05019057AA) and put at top rear corner of door module as shown in (Fig. 9) below. Do not allow Foam Tape to protrude past outside edge of door module. b. PM: cut 1.5 in Closed Cell Low Density Foam Tape, (p/n 05019058AA) and put at top rear corner of door module, inside outer lip as shown in (Fig. 10) below. Do not allow Foam Tape to protrude past outside edge of door module. 20. Turn door module over, (face up) and cut 6 lengths of Open Cell Foam Tape, (p/n 05019057AA) into 6.5 mm (.25 in.) strips lengthwise. Install on door bolster TOP and BOTTOM horizontal surfaces on the smooth surface where it meets door module opening. Start at the forward most section of the bolster to the rear most area of the horizontal surface isolating the Bolster from the mating surface of the door Panel Module. See (Fig. 4) above for front door. 21. Loosely install the longer bolt, (10 mm hex), for window regulator in bottom of door module. Thread bolt into door module so that threads protrude through module about 9.5 mm, (.375 in) then start threads into bottom of regulator. Bolt should now be threaded into door module and regulator with a space in between regulator and door module, similar to (Fig. 5) above. Be sure window regulator guide tab is in proper position in door module. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 8709 22. Position door module in door shell making sure to slip wiring to body, (at front of door), behind weatherstrip and guide window regulator and door latch mechanisms in place inside door shell. 23. Align top of door module in position and slide down in place. Lower window regulator bolt installed earlier in step Step # 21 should slide in "V" notch in bottom of door with regulator inside door shell. 24. Start, (do not tighten), all remaining bolts, (10 mm hex), for door module and window regulator. Tighten all bolts to 8 N.m (71 in. lbs.) 25. Install door latch screws, (T-30 Torx), Tighten to 7 N.m (62 in. lbs.). 26. Connect linkage(s) to door latch mechanism. 27. Position wire harness door bracket at front of door and install screws, (5 mm hex). Install weatherstrip. 28. Connect wire harness to body from door. 29. Install screw, (T-20 Torx), at inner door handle and replace trim. 30. Remove previously installed tape from door glass and slide door glass down making sure glass clips into regulator securely. 31. Install door bolster trim panel. 32. Install screw, (T-20 Torx), and trim cap at door pull cup. 33. Install manual window crank handle, (if equipped). 34. Install speaker screws and speaker grille. 35. Clean glass. 36. Repeat this process for other rear door. INSTRUMENT PANEL END CAP REPAIR PROCEDURE: 1. Loosen weatherstrip along front edge of instrument panel end cap. 2. Remove instrument panel end cap. 3. Cut 8 (.5 in.) pieces, (4 for each side) of Open Cell Foam Tape, (p/n 05019057AA). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 8710 4. Install 4 pieces of Open Cell Foam Tape at the mating surface for the cover as shown in # 1 (Fig. 11) below. 5. Cut 6 square pieces, (3 for each side) of Closed Cell Low Density Foam Tape, (p/n 05019058AA). 6. Stack 3 pieces of Closed Cell Low Density Foam Tape and cover top layer with Itch and Squeak Tape, (pin 05019054AA). Adhere stack towards the center area of cover on the end of the instrument panel as shown in #2 (Fig. 11) below. 7. Replace instrument panel end cover and reposition weatherstrip. 8. Repeat steps (1) through (7) for other side of instrument panel. 9. Reconnect battery negative cable. 10. Check operation of all door related systems, and audio functions. 11. Reset clock for customer satisfaction. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 23-009-07 Date: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 8711 070320 Interior - Buzz/Rattle From Front/Rear Door panels NUMBER: 23-009-07 GROUP: Body DATE: March 20, 2007 SUBJECT: Radio Speaker Misdiagnosis - Rattle/Buzz Sounds in Door Modules OVERVIEW: This bulletin involves removing the Bolster and Door Panel Modules and applying foam tape at critical points of wiring, actuator rods, panel connection points and the side Instrument Panel end caps. PARTS REQUIRED: MODELS: 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber SYMPTOM/CONDITION: Rattle or Buzz like sounds in the door module area, (front or rear). This is most noticeable with the radio on during high volume/deep base settings and is most likely caused by door links or wiring vibrating in the door module. The door module rattle or buzz sounds will not be heard with the radio off. Several areas of concern are involved and if the vehicle operator complains of rattles or buzz noises, perform the following Repair Procedure on ALL doors and both ends of Instrument Panel before replacing speakers. DIAGNOSIS: If the symptom/condition is present, perform the Repair Procedure. FRONT DOOR REPAIR PROCEDURE: 1. Lower the front windows: a. MK: 89 mm (3.5 in.) b. PM: 102 mm (4 in.) 2.5GLower the rear windows 152 mm (6 in.), (Preparing for rear door Repair Procedure). 3. Disconnect and isolate negative battery cable. 4. Pull weatherstrip off front of door at wire harness door bracket entering door. Remove 2 bolts, (5 mm hex), at retaining plate. Disconnect wire harness from body of vehicle. Pull wiring from behind weatherstrip. 5. Remove trim cap and screw, (T-20 Torx), at inside door handle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 8712 6. Remove manual window crank handle, (if equipped). 7. Remove interior trim flag for outside mirror, disconnect wire harness to electric mirror, (if equipped). 8. Using trim stick, remove speaker cover. 9. Remove top front and lower rear speaker screws only, (T-20 Torx). (Speaker will stay with door module). 10. Remove bolt(s), (10 mm hex), retaining door module near speaker: a. MK: 2 bolts. b. PM: 1 bolt. 11. Remove (2) longer bolts, (10 mm hex), retaining door module at bottom of door module. 12. Remove trim cap and screw, (T-20 Torx), at inside door pull cup. 13. Using trim stick, release bolster, swing down and allow to hang by tethers. 14. Release both window latches on regulator, pull up and roll back of window up to remove from door from the outside of door. Set glass aside on protected surface. 15. Remove bolts, (10 mm hex), behind bolster, (2 in regulators and 1 at center of door module). 16. Disconnect linkages at door latch to: a. Outside door handle, (both sides of vehicle). b. Lock cylinder, (drivers side only). 17. Remove (3) screws, (T-30 Torx), retaining latch to door. 18. Maneuver door module up, then forward, then down to remove from door. 19. Place removed door module face down on a clean, protected surface. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 8713 20. Remove wiring and convolute tubing from retainers and wrap with Open Cell Foam Tape, (p/n 05019057AA), in the areas described in below. Any wiring or convoluted tubing that is not wrapped or can come in contact with the door module shell should be wrapped with foam tape as shown in (Fig. 1) for MK and (Fig. 2) for PM. Reinstall wiring and convolute tubing in retainers. 21. Follow specific instructions based on vehicle below: a. MK: Cut the Closed Cell Low Density Foam Tape, (p/n 05019058AA) into 25 mm (1 in.) lengths and stack, (if needed), to back up actuator rods as shown in (Fig. 1), above. Place a piece of Itch and Squeak Tape, (p/n 05019054AA) on the top layer of Closed Cell Low Density Foam Tape where it contacts actuator rod. b. PM: Cut the Closed Cell Low Density Foam Tape, (p/n 05019058AA) into 12 mm (.5 in.) length to back up actuator rod as shown in (Fig. 3) below. NOTE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 8714 Actuator rod is removed and pulled from stay for easy installation 22. Turn door module over, (face up) and cut 6 lengths of Open Cell Foam Tape, (p/n 05019057AA) into 6.5 mm (.25 in.) strips lengthwise. Install on door bolster TOP and BOTTOM horizontal surfaces on the smooth surface where it meets door module opening. Start at the forward most section of the bolster to the rear most area of the horizontal surface isolating the Bolster from the mating surface of the door Panel Module. See (Fig. 4) below. Bottom of Bolster is shown, Top is similar. 23. Loosely install the lower bolt(s), (10 mm hex), for window regulator in bottom of door module. Thread bolt(s) into door module so that threads protrude through module about 12 mm, (.5 in.) then start threads into bottom of regulator. Bolt should now be threaded into door module and regulator with a space in between regulator and door module. Be sure window regulator guide tab is in proper position in door module. 24. Position door module in door shell making sure to slip wiring to body, (at front of door), behind weather-strip and guide window regulators and door latch mechanisms in place inside door shell. 25. Align top of door module in position and slide down in place. Lower window regulator bolts installed earlier in step Step # 23 should slide in "V" notch(s) in bottom of door with regulators inside door shell. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 8715 NOTE: Be sure mirror wiring protrudes through opening in top of door module. 26. Start, (do not tighten), all remaining bolts for door module and window regulators. Once all bolts are loosely installed, tighten all bolts to 8 N.m (71 in. lbs.) 27. Install door latch screws, (T-30 Torx), Tighten to 7 N.m (62 in. lbs.). 28. Connect linkage(s) to door latch mechanism. 29. Position wire harness door bracket at front of door and install screws, (5 mm hex). Install weatherstrip. 30. Connect wire harness to body from door. 31. Connect mirror wire harness, (if equipped) and install trim flag. 32. Install screw, (T-20 Torx), at inner door handle and replace trim. 33. Install door glass making sure glass clips into regulator securely. 34. Install door bolster trim panel. 35. Install screw, (T-20 Torx), and trim cap at door pull cup. 36. Install manual window crank handle, (if equipped). 37. Install speaker screws, (T-20 Torx), and speaker grille. 38. Clean glass. 39. Repeat this process for other front door. REAR DOOR REPAIR PROCEDURE: 1. Pull weatherstrip off front of door at wire harness bracket entering door. Remove 2 bolts, (5 mm hex) at wire harness door bracket. Disconnect wire harness from body of vehicle. 2. Remove trim cap and screw, (T-20 Torx), at inside door handle. 3. Remove manual window crank handle, (if equipped). 4. Using trim stick, remove speaker cover. 5. Remove top front and lower rear speaker screws only. (Speaker will remain with door module). 6. Remove bolt(s), (10 mm hex), retaining door module near speaker. a. MK: 2 bolts b. PM: 1 bolt 7. Remove (1) longer bolt, (10 mm hex), retaining door module and window regulator at bottom of door module. 8. Remove trim cap and screw, (1-20 Torx), at inside door pull cup. 9. Using trim stick, release bolster, swing down and allow to hang by tethers. 10. Release window latch retainer at bottom of glass from regulator. 11. Slide glass up in frame and duct tape from outside of window, up over frame to inside of window in the full UP position. 12. Remove bolts, (10 mm hex) behind bolster: a. MK: 2 in regulator and 1 at center of door module. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 8716 b. PM: 1 in regulator, 2 in window motor brace and 1 in door module. 13. Disconnect linkage(s) at latch to: a. MK49 - Compass 1). Outside door handle and 2). Fulcrum. b. MK74 - Patriot and PM - Caliber Outside door handle. 14. Remove (3) screws, (T-30 Torx), retaining latch to door. 15. Maneuver door module up, then forward, then down to remove from door. 16. Place removed door module face down on a clean, protected surface. 17. Follow specific instructions based on vehicle below: a. MK: Remove wiring and convolute tubing from retainers and wrap with Open Cell Foam Tape, (p/n 05019057AA) in the areas described in below. Any wiring or convoluted tubing that is not wrapped or can come in contact with the door module shell should be wrapped with foam tape as shown in (Fig. 6) below. Reinstall wiring and convolute tubing back in retainers. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 8717 b. PM: Remove wiring and convolute tubing from retainers and wrap with Open Cell Foam Tape, (p/n 05019057AA) in the areas described in below. Any wiring or convoluted tubing that is not wrapped or can come in contact with the door module shell should be wrapped with foam tape as shown in (Fig. 7) below. Reinstall wiring and convolute tubing back in retainers. 18. Cut the Closed Cell Low Density Foam Tape, (p/n 05019058AA) into 1" lengths and stack (if needed) to back up actuator rods with Itch and Squeak Tape, (p/n 05019054AA) as top layer, as shown in (Fig. 8) below. NOTE: If # 2 below is not existing, install it. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 8718 19. Follow specific instructions based on vehicle below: a. MK: cut 12 mm (.5 in) Open Cell Foam Tape, (p/n 05019057AA) and put at top rear corner of door module as shown in (Fig. 9) below. Do not allow Foam Tape to protrude past outside edge of door module. b. PM: cut 1.5 in Closed Cell Low Density Foam Tape, (p/n 05019058AA) and put at top rear corner of door module, inside outer lip as shown in (Fig. 10) below. Do not allow Foam Tape to protrude past outside edge of door module. 20. Turn door module over, (face up) and cut 6 lengths of Open Cell Foam Tape, (p/n 05019057AA) into 6.5 mm (.25 in.) strips lengthwise. Install on door bolster TOP and BOTTOM horizontal surfaces on the smooth surface where it meets door module opening. Start at the forward most section of the bolster to the rear most area of the horizontal surface isolating the Bolster from the mating surface of the door Panel Module. See (Fig. 4) above for front door. 21. Loosely install the longer bolt, (10 mm hex), for window regulator in bottom of door module. Thread bolt into door module so that threads protrude through module about 9.5 mm, (.375 in) then start threads into bottom of regulator. Bolt should now be threaded into door module and regulator with a space in between regulator and door module, similar to (Fig. 5) above. Be sure window regulator guide tab is in proper position in door module. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 8719 22. Position door module in door shell making sure to slip wiring to body, (at front of door), behind weatherstrip and guide window regulator and door latch mechanisms in place inside door shell. 23. Align top of door module in position and slide down in place. Lower window regulator bolt installed earlier in step Step # 21 should slide in "V" notch in bottom of door with regulator inside door shell. 24. Start, (do not tighten), all remaining bolts, (10 mm hex), for door module and window regulator. Tighten all bolts to 8 N.m (71 in. lbs.) 25. Install door latch screws, (T-30 Torx), Tighten to 7 N.m (62 in. lbs.). 26. Connect linkage(s) to door latch mechanism. 27. Position wire harness door bracket at front of door and install screws, (5 mm hex). Install weatherstrip. 28. Connect wire harness to body from door. 29. Install screw, (T-20 Torx), at inner door handle and replace trim. 30. Remove previously installed tape from door glass and slide door glass down making sure glass clips into regulator securely. 31. Install door bolster trim panel. 32. Install screw, (T-20 Torx), and trim cap at door pull cup. 33. Install manual window crank handle, (if equipped). 34. Install speaker screws and speaker grille. 35. Clean glass. 36. Repeat this process for other rear door. INSTRUMENT PANEL END CAP REPAIR PROCEDURE: 1. Loosen weatherstrip along front edge of instrument panel end cap. 2. Remove instrument panel end cap. 3. Cut 8 (.5 in.) pieces, (4 for each side) of Open Cell Foam Tape, (p/n 05019057AA). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 8720 4. Install 4 pieces of Open Cell Foam Tape at the mating surface for the cover as shown in # 1 (Fig. 11) below. 5. Cut 6 square pieces, (3 for each side) of Closed Cell Low Density Foam Tape, (p/n 05019058AA). 6. Stack 3 pieces of Closed Cell Low Density Foam Tape and cover top layer with Itch and Squeak Tape, (pin 05019054AA). Adhere stack towards the center area of cover on the end of the instrument panel as shown in #2 (Fig. 11) below. 7. Replace instrument panel end cover and reposition weatherstrip. 8. Repeat steps (1) through (7) for other side of instrument panel. 9. Reconnect battery negative cable. 10. Check operation of all door related systems, and audio functions. 11. Reset clock for customer satisfaction. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Door-Plugs Front Door Panel: Service and Repair Door-Plugs Removal REMOVAL 1. Remove screw (1) and handle plug (6). 2. Using trim stick C-4755, remove mirror flag plug (2). 3. Using trim stick C-4755 remove speaker grille (5). 4. Remove screws (3) and (4) fastening speaker to door (7). Installation INSTALLATION 1. Install speaker screws (3) and (4) fastening speaker to door. 2. Hand tap speaker grille to door (7). 3. Install handle plug (6) and screw (1) to door. 4. Hand tap mirror flag (2) to door (7). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Door-Plugs > Page 8723 Front Door Panel: Service and Repair Front Door - Bolster Removal REMOVAL 1. Remove pull-cup screw (1). 2. Remove window crank (1) from spindle if equipped. 3. Using trim stick C-4755, start at the lower corner and pull in the direction of the arrows. Bolster should unsnap. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Door-Plugs > Page 8724 4. Remove sock seal (1) and (3) that wraps around switch bezel and wire harness. Disconnect wire connectors (2). 5. Remove switch bezel from bolster. 6. Remove bolster by unsnapping plastic tethers (1) from bolster back side of surface. Installation INSTALLATION 1. Connect bolster to door module tethers (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Door-Plugs > Page 8725 2. Connect wire connectors (2) and close sock seal (1). 3. Replace window crank (1) to spindle. 4. Replace pull cup screw. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Door-Plugs > Page 8726 Front Door Panel: Service and Repair Speaker And Grille Removal REMOVAL 1. Using trim stick C-4755, find service notch (1) located at the bottom of speaker grille and pry up speaker grille. 2. Remove two screws attaching speaker to door panel (3). 3. Remove two screws attaching speaker (2) to door module (1). 4. Disconnect wire connector. Installation INSTALLATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Door-Plugs > Page 8727 1. Connect wire connector. 2. Install speaker (2) into panel (3) and install two screws into door panel. 3. Install two screws into trim panel (1). 4. Install speaker grille (1) onto trim panel (3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Service and Repair > Removal Front Door Striker: Service and Repair Removal REMOVAL 1. Remove fasteners (2) from door jamb. 2. Remove door striker (1) from vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Service and Repair > Removal > Page 8732 Front Door Striker: Service and Repair Installation INSTALLATION 1. Install striker (1) onto door jamb. 2. Install fasteners (2) into striker. 3. Tighten fasteners to 26 Nm (19 ft. lbs.) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Service and Repair > Removal Front Door Window Glass: Service and Repair Removal REMOVAL 1. Remove bolster. 2. Move glass to line up snap plates with access holes (1). 3. Using a punch or equivalent, press tabs releasing glass from window regulator. 4. Manually move glass upward to full up position and remove from window frame. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Service and Repair > Removal > Page 8737 Front Door Window Glass: Service and Repair Installation INSTALLATION 1. Insert glass into glass channel and slide down ensuring access holes (1) align with snaps. 2. Ensure access holes properly lock into snaps (1). 3. Install bolster. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Technical Service Bulletins > Customer Interest for Front Door Window Regulator: > 23-028-08 > Sep > 08 > Body - Noise When Operating Front/Rear Door Windows Front Door Window Regulator: Customer Interest Body - Noise When Operating Front/Rear Door Windows NUMBER: 23-028-08 GROUP: Body DATE: September 19, 2008 SUBJECT: Squeak or Groan Sound When Raising or Lowering Door Glass OVERVIEW: This bulletin involves lubricating the window regulator rails. MODELS: 2006 - 2007 (CS) Pacifica 2007 - 2008 (LX) 300/Magnum/Charger 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber NOTE: This bulletin applies to all 2006 - 2007 CS, 2007 - 2008 LX vehicles built before November 14th, 2007 (MDH 1114XX) and PM/MK vehicles built before May 13th 2008 (MDH 0513XX). SYMPTOM/CONDITION: Squeak or squealing sound from window regulator area when raising or lowering front or rear door glass. Groaning sound when cycling front or rear door glass to full up position. DIAGNOSIS: If the customer describes the Symptom/Condition, verify the sound is from the regulator and is not being caused by glass run seals or belt seals. If the condition is present, perform the Repair Procedure on the door. PARTS REQUIRED: REPAIR PROCEDURE - PM/MK: 1. Remove door trim bolster. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > PANEL, Door Trim > Removal > REMOVAL. 2. Remove the door speaker cover and speaker. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 08 - Electrical > 8A - Audio > Speaker > Removal > Removal. 3. Lower regulator to a position where forward (white) slider is visible through opening. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Technical Service Bulletins > Customer Interest for Front Door Window Regulator: > 23-028-08 > Sep > 08 > Body - Noise When Operating Front/Rear Door Windows > Page 8746 4. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers (Fig 1). 5. Move regulator to position where rear (white) slider is visible through opening. 6. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers (Fig 2). 7. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 8. Install the door speaker and cover. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 08 - Electrical > 8A - Audio > Speaker > Installation > Installation. 9. Install door trim bolster. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 10. Repeat the lubrication process only on doors that have a regulator squeak or groan sound issue. REPAIR PROCEDURE - CS: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Technical Service Bulletins > Customer Interest for Front Door Window Regulator: > 23-028-08 > Sep > 08 > Body - Noise When Operating Front/Rear Door Windows > Page 8747 1. Remove door trim panel and watershield to access regulator rails and sliders. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Removal > Removal. 2. Lower regulator to a position where forward (white) slider is visible through opening. 3. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 4. Move regulator to position where rear (white) slider is visible through opening. 5. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 6. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 7. Install watershield and door trim panel. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 8. Repeat the lubrication process only on doors that have a regulator squeak or groan issue. REPAIR PROCEDURE - LX: 1. Remove door trim panel and watershield to access regulator rails and sliders. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Removal > Removal. 2. Lower regulator to a position where forward (white) slider is visible through opening. 3. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 4. Move regulator to position where rear (white) slider is visible through opening. 5. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 6. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 7. Install watershield and door trim panel. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 8. Repeat the lubrication process only on doors that have a regulator squeak or groan issue. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Technical Service Bulletins > Customer Interest for Front Door Window Regulator: > 23-028-08 > Sep > 08 > Body - Noise When Operating Front/Rear Door Windows > Page 8748 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > 23-028-08 > Sep > 08 > Body - Noise When Operating Front/Rear Door Windows Front Door Window Regulator: All Technical Service Bulletins Body - Noise When Operating Front/Rear Door Windows NUMBER: 23-028-08 GROUP: Body DATE: September 19, 2008 SUBJECT: Squeak or Groan Sound When Raising or Lowering Door Glass OVERVIEW: This bulletin involves lubricating the window regulator rails. MODELS: 2006 - 2007 (CS) Pacifica 2007 - 2008 (LX) 300/Magnum/Charger 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber NOTE: This bulletin applies to all 2006 - 2007 CS, 2007 - 2008 LX vehicles built before November 14th, 2007 (MDH 1114XX) and PM/MK vehicles built before May 13th 2008 (MDH 0513XX). SYMPTOM/CONDITION: Squeak or squealing sound from window regulator area when raising or lowering front or rear door glass. Groaning sound when cycling front or rear door glass to full up position. DIAGNOSIS: If the customer describes the Symptom/Condition, verify the sound is from the regulator and is not being caused by glass run seals or belt seals. If the condition is present, perform the Repair Procedure on the door. PARTS REQUIRED: REPAIR PROCEDURE - PM/MK: 1. Remove door trim bolster. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > PANEL, Door Trim > Removal > REMOVAL. 2. Remove the door speaker cover and speaker. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 08 - Electrical > 8A - Audio > Speaker > Removal > Removal. 3. Lower regulator to a position where forward (white) slider is visible through opening. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > 23-028-08 > Sep > 08 > Body - Noise When Operating Front/Rear Door Windows > Page 8754 4. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers (Fig 1). 5. Move regulator to position where rear (white) slider is visible through opening. 6. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers (Fig 2). 7. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 8. Install the door speaker and cover. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 08 - Electrical > 8A - Audio > Speaker > Installation > Installation. 9. Install door trim bolster. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 10. Repeat the lubrication process only on doors that have a regulator squeak or groan sound issue. REPAIR PROCEDURE - CS: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > 23-028-08 > Sep > 08 > Body - Noise When Operating Front/Rear Door Windows > Page 8755 1. Remove door trim panel and watershield to access regulator rails and sliders. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Removal > Removal. 2. Lower regulator to a position where forward (white) slider is visible through opening. 3. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 4. Move regulator to position where rear (white) slider is visible through opening. 5. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 6. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 7. Install watershield and door trim panel. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 8. Repeat the lubrication process only on doors that have a regulator squeak or groan issue. REPAIR PROCEDURE - LX: 1. Remove door trim panel and watershield to access regulator rails and sliders. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Removal > Removal. 2. Lower regulator to a position where forward (white) slider is visible through opening. 3. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 4. Move regulator to position where rear (white) slider is visible through opening. 5. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 6. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 7. Install watershield and door trim panel. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 8. Repeat the lubrication process only on doors that have a regulator squeak or groan issue. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > 23-028-08 > Sep > 08 > Body - Noise When Operating Front/Rear Door Windows > Page 8756 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page 8757 Front Door Window Regulator: By Symptom Technical Service Bulletin # 23-028-08 Date: 080919 Body - Noise When Operating Front/Rear Door Windows NUMBER: 23-028-08 GROUP: Body DATE: September 19, 2008 SUBJECT: Squeak or Groan Sound When Raising or Lowering Door Glass OVERVIEW: This bulletin involves lubricating the window regulator rails. MODELS: 2006 - 2007 (CS) Pacifica 2007 - 2008 (LX) 300/Magnum/Charger 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber NOTE: This bulletin applies to all 2006 - 2007 CS, 2007 - 2008 LX vehicles built before November 14th, 2007 (MDH 1114XX) and PM/MK vehicles built before May 13th 2008 (MDH 0513XX). SYMPTOM/CONDITION: Squeak or squealing sound from window regulator area when raising or lowering front or rear door glass. Groaning sound when cycling front or rear door glass to full up position. DIAGNOSIS: If the customer describes the Symptom/Condition, verify the sound is from the regulator and is not being caused by glass run seals or belt seals. If the condition is present, perform the Repair Procedure on the door. PARTS REQUIRED: REPAIR PROCEDURE - PM/MK: 1. Remove door trim bolster. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > PANEL, Door Trim > Removal > REMOVAL. 2. Remove the door speaker cover and speaker. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 08 - Electrical > 8A - Audio > Speaker > Removal > Removal. 3. Lower regulator to a position where forward (white) slider is visible through opening. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page 8758 4. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers (Fig 1). 5. Move regulator to position where rear (white) slider is visible through opening. 6. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers (Fig 2). 7. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 8. Install the door speaker and cover. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 08 - Electrical > 8A - Audio > Speaker > Installation > Installation. 9. Install door trim bolster. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 10. Repeat the lubrication process only on doors that have a regulator squeak or groan sound issue. REPAIR PROCEDURE - CS: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page 8759 1. Remove door trim panel and watershield to access regulator rails and sliders. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Removal > Removal. 2. Lower regulator to a position where forward (white) slider is visible through opening. 3. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 4. Move regulator to position where rear (white) slider is visible through opening. 5. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 6. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 7. Install watershield and door trim panel. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 8. Repeat the lubrication process only on doors that have a regulator squeak or groan issue. REPAIR PROCEDURE - LX: 1. Remove door trim panel and watershield to access regulator rails and sliders. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Removal > Removal. 2. Lower regulator to a position where forward (white) slider is visible through opening. 3. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 4. Move regulator to position where rear (white) slider is visible through opening. 5. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 6. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 7. Install watershield and door trim panel. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 8. Repeat the lubrication process only on doors that have a regulator squeak or groan issue. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page 8760 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 23-028-08 Date: 080919 Body - Noise When Operating Front/Rear Door Windows NUMBER: 23-028-08 GROUP: Body DATE: September 19, 2008 SUBJECT: Squeak or Groan Sound When Raising or Lowering Door Glass OVERVIEW: This bulletin involves lubricating the window regulator rails. MODELS: 2006 - 2007 (CS) Pacifica 2007 - 2008 (LX) 300/Magnum/Charger 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber NOTE: This bulletin applies to all 2006 - 2007 CS, 2007 - 2008 LX vehicles built before November 14th, 2007 (MDH 1114XX) and PM/MK vehicles built before May 13th 2008 (MDH 0513XX). SYMPTOM/CONDITION: Squeak or squealing sound from window regulator area when raising or lowering front or rear door glass. Groaning sound when cycling front or rear door glass to full up position. DIAGNOSIS: If the customer describes the Symptom/Condition, verify the sound is from the regulator and is not being caused by glass run seals or belt seals. If the condition is present, perform the Repair Procedure on the door. PARTS REQUIRED: REPAIR PROCEDURE - PM/MK: 1. Remove door trim bolster. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > PANEL, Door Trim > Removal > REMOVAL. 2. Remove the door speaker cover and speaker. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 08 - Electrical > 8A - Audio > Speaker > Removal > Removal. 3. Lower regulator to a position where forward (white) slider is visible through opening. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page 8761 4. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers (Fig 1). 5. Move regulator to position where rear (white) slider is visible through opening. 6. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers (Fig 2). 7. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 8. Install the door speaker and cover. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 08 - Electrical > 8A - Audio > Speaker > Installation > Installation. 9. Install door trim bolster. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 10. Repeat the lubrication process only on doors that have a regulator squeak or groan sound issue. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page 8762 REPAIR PROCEDURE - CS: 1. Remove door trim panel and watershield to access regulator rails and sliders. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Removal > Removal. 2. Lower regulator to a position where forward (white) slider is visible through opening. 3. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 4. Move regulator to position where rear (white) slider is visible through opening. 5. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 6. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 7. Install watershield and door trim panel. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 8. Repeat the lubrication process only on doors that have a regulator squeak or groan issue. REPAIR PROCEDURE - LX: 1. Remove door trim panel and watershield to access regulator rails and sliders. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Removal > Removal. 2. Lower regulator to a position where forward (white) slider is visible through opening. 3. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 4. Move regulator to position where rear (white) slider is visible through opening. 5. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 6. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 7. Install watershield and door trim panel. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 8. Repeat the lubrication process only on doors that have a regulator squeak or groan issue. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page 8763 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Removal Front Door Window Regulator: Service and Repair Removal REMOVAL 1. Remove bolster. 2. Remove door plugs. 3. If equipped, remove window crank (1). 4. Remove glass. 5. Remove power motor attachment screws (1) from front side of trim panel. (For manual windows only, unsnap manual drive from drum housing). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Removal > Page 8766 6. Remove lower attachment bolts through front side of trim panel for Window Regulator rails (7). CAUTION: Use care when disconnecting connectors to avoid damaging components. 7. Disconnect wire harness (10) from power motor on back of trim panel. 8. Remove rails for towers on back side of trim panel. 9. Remove window regulator (5) from trim panel. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Removal > Page 8767 Front Door Window Regulator: Service and Repair Installation INSTALLATION 1. Install window regulator (5) to door module (6). 2. Install rails (5) back to trim panel. CAUTION: Use care when connecting connectors to avoid damaging components. 3. Connect wire harness (10). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair > Removal Rear Door Exterior Handle: Service and Repair Removal REMOVAL 1. Remove door plugs. 2. Remove bolster. 3. Remove door module. 4. Remove rod link (1). 5. Remove fasteners (3). 6. Remove handle (2) from door. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair > Removal > Page 8774 Rear Door Exterior Handle: Service and Repair Installation INSTALLATION 1. Install door handle (2). 2. Install three fasteners. Tighten to 8 Nm (6 ft. lbs.). 3. Install rod link (1). 4. Install door module. 5. Install bolster. 6. Install door plugs. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > Customer Interest for Rear Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises Rear Door Hinge: Customer Interest Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > Customer Interest for Rear Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 8783 This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > Customer Interest for Rear Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 8784 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises Rear Door Hinge: All Technical Service Bulletins Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 8790 This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 8791 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > Page 8792 Rear Door Hinge: By Symptom Technical Service Bulletin # 23-018-10 Date: 101021 Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > Page 8793 SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > Page 8794 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 23-018-10 Date: 101021 Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > Page 8795 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > Page 8796 CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Removal Rear Door Hinge: Service and Repair Removal REMOVAL 1. Disconnect wire harness (4). 2. Remove nuts (1) fastening door hinge (2) to door studs. 3. With the help of an assistant, remove door (7) from vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Removal > Page 8799 Rear Door Hinge: Service and Repair Installation INSTALLATION 1. With the help of an assistant, have the assistant align door studs through hinge (2). 2. Install nuts and torque nuts to Nm ( ft. lbs.) 3. Connect wire connector (4). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Adjustments Rear Door Latch: Adjustments REAR DOOR LATCH ADJUSTMENT 1. Insert a Torx(R) wrench through the elongated hole in the door end frame near the latch striker opening. 2. Loosen screw on the side of the latch linkage. 3. Push button on outside door handle and release it. 4. Tighten screw on latch. 5. Verify latch operation. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Removal Rear Door Latch: Service and Repair Removal REMOVAL 1. Remove window crank handle (4) and washer if equipped. 2. Remove rear door trim bolster. 3. Remove door plugs. 4. Remove rear door module. 5. If equipped, remove wire connector. 6. Remove latch rod (4) from latch (3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Removal > Page 8805 7. Remove fasteners (4) from latch (2). 8. Remove latch from door. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Removal > Page 8806 Rear Door Latch: Service and Repair Installation INSTALLATION 1. Install latch into door (1) and align latch (2) with fastener openings. 2. Install fasteners (4) into latch (2). Tighten to 9 Nm (7ft.lbs.) 3. Connect rod (4) to latch (3). 4. If equipped, connect wire connector to latch. 5. Install door module. 6. Install bolster. 7. Install door plugs. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Removal > Page 8807 8. If equipped, install window crank (4) and washer. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Customer Interest for Rear Door Panel: > 23-009-07 > Mar > 07 > Interior Buzz/Rattle From Front/Rear Door panels Rear Door Panel: Customer Interest Interior - Buzz/Rattle From Front/Rear Door panels NUMBER: 23-009-07 GROUP: Body DATE: March 20, 2007 SUBJECT: Radio Speaker Misdiagnosis - Rattle/Buzz Sounds in Door Modules OVERVIEW: This bulletin involves removing the Bolster and Door Panel Modules and applying foam tape at critical points of wiring, actuator rods, panel connection points and the side Instrument Panel end caps. PARTS REQUIRED: MODELS: 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber SYMPTOM/CONDITION: Rattle or Buzz like sounds in the door module area, (front or rear). This is most noticeable with the radio on during high volume/deep base settings and is most likely caused by door links or wiring vibrating in the door module. The door module rattle or buzz sounds will not be heard with the radio off. Several areas of concern are involved and if the vehicle operator complains of rattles or buzz noises, perform the following Repair Procedure on ALL doors and both ends of Instrument Panel before replacing speakers. DIAGNOSIS: If the symptom/condition is present, perform the Repair Procedure. FRONT DOOR REPAIR PROCEDURE: 1. Lower the front windows: a. MK: 89 mm (3.5 in.) b. PM: 102 mm (4 in.) 2.5GLower the rear windows 152 mm (6 in.), (Preparing for rear door Repair Procedure). 3. Disconnect and isolate negative battery cable. 4. Pull weatherstrip off front of door at wire harness door bracket entering door. Remove 2 bolts, (5 mm hex), at retaining plate. Disconnect wire harness from body of vehicle. Pull wiring from behind weatherstrip. 5. Remove trim cap and screw, (T-20 Torx), at inside door handle. 6. Remove manual window crank handle, (if equipped). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Customer Interest for Rear Door Panel: > 23-009-07 > Mar > 07 > Interior Buzz/Rattle From Front/Rear Door panels > Page 8816 7. Remove interior trim flag for outside mirror, disconnect wire harness to electric mirror, (if equipped). 8. Using trim stick, remove speaker cover. 9. Remove top front and lower rear speaker screws only, (T-20 Torx). (Speaker will stay with door module). 10. Remove bolt(s), (10 mm hex), retaining door module near speaker: a. MK: 2 bolts. b. PM: 1 bolt. 11. Remove (2) longer bolts, (10 mm hex), retaining door module at bottom of door module. 12. Remove trim cap and screw, (T-20 Torx), at inside door pull cup. 13. Using trim stick, release bolster, swing down and allow to hang by tethers. 14. Release both window latches on regulator, pull up and roll back of window up to remove from door from the outside of door. Set glass aside on protected surface. 15. Remove bolts, (10 mm hex), behind bolster, (2 in regulators and 1 at center of door module). 16. Disconnect linkages at door latch to: a. Outside door handle, (both sides of vehicle). b. Lock cylinder, (drivers side only). 17. Remove (3) screws, (T-30 Torx), retaining latch to door. 18. Maneuver door module up, then forward, then down to remove from door. 19. Place removed door module face down on a clean, protected surface. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Customer Interest for Rear Door Panel: > 23-009-07 > Mar > 07 > Interior Buzz/Rattle From Front/Rear Door panels > Page 8817 20. Remove wiring and convolute tubing from retainers and wrap with Open Cell Foam Tape, (p/n 05019057AA), in the areas described in below. Any wiring or convoluted tubing that is not wrapped or can come in contact with the door module shell should be wrapped with foam tape as shown in (Fig. 1) for MK and (Fig. 2) for PM. Reinstall wiring and convolute tubing in retainers. 21. Follow specific instructions based on vehicle below: a. MK: Cut the Closed Cell Low Density Foam Tape, (p/n 05019058AA) into 25 mm (1 in.) lengths and stack, (if needed), to back up actuator rods as shown in (Fig. 1), above. Place a piece of Itch and Squeak Tape, (p/n 05019054AA) on the top layer of Closed Cell Low Density Foam Tape where it contacts actuator rod. b. PM: Cut the Closed Cell Low Density Foam Tape, (p/n 05019058AA) into 12 mm (.5 in.) length to back up actuator rod as shown in (Fig. 3) below. NOTE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Customer Interest for Rear Door Panel: > 23-009-07 > Mar > 07 > Interior Buzz/Rattle From Front/Rear Door panels > Page 8818 Actuator rod is removed and pulled from stay for easy installation 22. Turn door module over, (face up) and cut 6 lengths of Open Cell Foam Tape, (p/n 05019057AA) into 6.5 mm (.25 in.) strips lengthwise. Install on door bolster TOP and BOTTOM horizontal surfaces on the smooth surface where it meets door module opening. Start at the forward most section of the bolster to the rear most area of the horizontal surface isolating the Bolster from the mating surface of the door Panel Module. See (Fig. 4) below. Bottom of Bolster is shown, Top is similar. 23. Loosely install the lower bolt(s), (10 mm hex), for window regulator in bottom of door module. Thread bolt(s) into door module so that threads protrude through module about 12 mm, (.5 in.) then start threads into bottom of regulator. Bolt should now be threaded into door module and regulator with a space in between regulator and door module. Be sure window regulator guide tab is in proper position in door module. 24. Position door module in door shell making sure to slip wiring to body, (at front of door), behind weather-strip and guide window regulators and door latch mechanisms in place inside door shell. 25. Align top of door module in position and slide down in place. Lower window regulator bolts installed earlier in step Step # 23 should slide in "V" notch(s) in bottom of door with regulators inside door shell. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Customer Interest for Rear Door Panel: > 23-009-07 > Mar > 07 > Interior Buzz/Rattle From Front/Rear Door panels > Page 8819 NOTE: Be sure mirror wiring protrudes through opening in top of door module. 26. Start, (do not tighten), all remaining bolts for door module and window regulators. Once all bolts are loosely installed, tighten all bolts to 8 N.m (71 in. lbs.) 27. Install door latch screws, (T-30 Torx), Tighten to 7 N.m (62 in. lbs.). 28. Connect linkage(s) to door latch mechanism. 29. Position wire harness door bracket at front of door and install screws, (5 mm hex). Install weatherstrip. 30. Connect wire harness to body from door. 31. Connect mirror wire harness, (if equipped) and install trim flag. 32. Install screw, (T-20 Torx), at inner door handle and replace trim. 33. Install door glass making sure glass clips into regulator securely. 34. Install door bolster trim panel. 35. Install screw, (T-20 Torx), and trim cap at door pull cup. 36. Install manual window crank handle, (if equipped). 37. Install speaker screws, (T-20 Torx), and speaker grille. 38. Clean glass. 39. Repeat this process for other front door. REAR DOOR REPAIR PROCEDURE: 1. Pull weatherstrip off front of door at wire harness bracket entering door. Remove 2 bolts, (5 mm hex) at wire harness door bracket. Disconnect wire harness from body of vehicle. 2. Remove trim cap and screw, (T-20 Torx), at inside door handle. 3. Remove manual window crank handle, (if equipped). 4. Using trim stick, remove speaker cover. 5. Remove top front and lower rear speaker screws only. (Speaker will remain with door module). 6. Remove bolt(s), (10 mm hex), retaining door module near speaker. a. MK: 2 bolts b. PM: 1 bolt 7. Remove (1) longer bolt, (10 mm hex), retaining door module and window regulator at bottom of door module. 8. Remove trim cap and screw, (1-20 Torx), at inside door pull cup. 9. Using trim stick, release bolster, swing down and allow to hang by tethers. 10. Release window latch retainer at bottom of glass from regulator. 11. Slide glass up in frame and duct tape from outside of window, up over frame to inside of window in the full UP position. 12. Remove bolts, (10 mm hex) behind bolster: a. MK: 2 in regulator and 1 at center of door module. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Customer Interest for Rear Door Panel: > 23-009-07 > Mar > 07 > Interior Buzz/Rattle From Front/Rear Door panels > Page 8820 b. PM: 1 in regulator, 2 in window motor brace and 1 in door module. 13. Disconnect linkage(s) at latch to: a. MK49 - Compass 1). Outside door handle and 2). Fulcrum. b. MK74 - Patriot and PM - Caliber Outside door handle. 14. Remove (3) screws, (T-30 Torx), retaining latch to door. 15. Maneuver door module up, then forward, then down to remove from door. 16. Place removed door module face down on a clean, protected surface. 17. Follow specific instructions based on vehicle below: a. MK: Remove wiring and convolute tubing from retainers and wrap with Open Cell Foam Tape, (p/n 05019057AA) in the areas described in below. Any wiring or convoluted tubing that is not wrapped or can come in contact with the door module shell should be wrapped with foam tape as shown in (Fig. 6) below. Reinstall wiring and convolute tubing back in retainers. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Customer Interest for Rear Door Panel: > 23-009-07 > Mar > 07 > Interior Buzz/Rattle From Front/Rear Door panels > Page 8821 b. PM: Remove wiring and convolute tubing from retainers and wrap with Open Cell Foam Tape, (p/n 05019057AA) in the areas described in below. Any wiring or convoluted tubing that is not wrapped or can come in contact with the door module shell should be wrapped with foam tape as shown in (Fig. 7) below. Reinstall wiring and convolute tubing back in retainers. 18. Cut the Closed Cell Low Density Foam Tape, (p/n 05019058AA) into 1" lengths and stack (if needed) to back up actuator rods with Itch and Squeak Tape, (p/n 05019054AA) as top layer, as shown in (Fig. 8) below. NOTE: If # 2 below is not existing, install it. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Customer Interest for Rear Door Panel: > 23-009-07 > Mar > 07 > Interior Buzz/Rattle From Front/Rear Door panels > Page 8822 19. Follow specific instructions based on vehicle below: a. MK: cut 12 mm (.5 in) Open Cell Foam Tape, (p/n 05019057AA) and put at top rear corner of door module as shown in (Fig. 9) below. Do not allow Foam Tape to protrude past outside edge of door module. b. PM: cut 1.5 in Closed Cell Low Density Foam Tape, (p/n 05019058AA) and put at top rear corner of door module, inside outer lip as shown in (Fig. 10) below. Do not allow Foam Tape to protrude past outside edge of door module. 20. Turn door module over, (face up) and cut 6 lengths of Open Cell Foam Tape, (p/n 05019057AA) into 6.5 mm (.25 in.) strips lengthwise. Install on door bolster TOP and BOTTOM horizontal surfaces on the smooth surface where it meets door module opening. Start at the forward most section of the bolster to the rear most area of the horizontal surface isolating the Bolster from the mating surface of the door Panel Module. See (Fig. 4) above for front door. 21. Loosely install the longer bolt, (10 mm hex), for window regulator in bottom of door module. Thread bolt into door module so that threads protrude through module about 9.5 mm, (.375 in) then start threads into bottom of regulator. Bolt should now be threaded into door module and regulator with a space in between regulator and door module, similar to (Fig. 5) above. Be sure window regulator guide tab is in proper position in door module. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Customer Interest for Rear Door Panel: > 23-009-07 > Mar > 07 > Interior Buzz/Rattle From Front/Rear Door panels > Page 8823 22. Position door module in door shell making sure to slip wiring to body, (at front of door), behind weatherstrip and guide window regulator and door latch mechanisms in place inside door shell. 23. Align top of door module in position and slide down in place. Lower window regulator bolt installed earlier in step Step # 21 should slide in "V" notch in bottom of door with regulator inside door shell. 24. Start, (do not tighten), all remaining bolts, (10 mm hex), for door module and window regulator. Tighten all bolts to 8 N.m (71 in. lbs.) 25. Install door latch screws, (T-30 Torx), Tighten to 7 N.m (62 in. lbs.). 26. Connect linkage(s) to door latch mechanism. 27. Position wire harness door bracket at front of door and install screws, (5 mm hex). Install weatherstrip. 28. Connect wire harness to body from door. 29. Install screw, (T-20 Torx), at inner door handle and replace trim. 30. Remove previously installed tape from door glass and slide door glass down making sure glass clips into regulator securely. 31. Install door bolster trim panel. 32. Install screw, (T-20 Torx), and trim cap at door pull cup. 33. Install manual window crank handle, (if equipped). 34. Install speaker screws and speaker grille. 35. Clean glass. 36. Repeat this process for other rear door. INSTRUMENT PANEL END CAP REPAIR PROCEDURE: 1. Loosen weatherstrip along front edge of instrument panel end cap. 2. Remove instrument panel end cap. 3. Cut 8 (.5 in.) pieces, (4 for each side) of Open Cell Foam Tape, (p/n 05019057AA). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Customer Interest for Rear Door Panel: > 23-009-07 > Mar > 07 > Interior Buzz/Rattle From Front/Rear Door panels > Page 8824 4. Install 4 pieces of Open Cell Foam Tape at the mating surface for the cover as shown in # 1 (Fig. 11) below. 5. Cut 6 square pieces, (3 for each side) of Closed Cell Low Density Foam Tape, (p/n 05019058AA). 6. Stack 3 pieces of Closed Cell Low Density Foam Tape and cover top layer with Itch and Squeak Tape, (pin 05019054AA). Adhere stack towards the center area of cover on the end of the instrument panel as shown in #2 (Fig. 11) below. 7. Replace instrument panel end cover and reposition weatherstrip. 8. Repeat steps (1) through (7) for other side of instrument panel. 9. Reconnect battery negative cable. 10. Check operation of all door related systems, and audio functions. 11. Reset clock for customer satisfaction. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > 23-009-07 > Mar > 07 > Interior - Buzz/Rattle From Front/Rear Door panels Rear Door Panel: All Technical Service Bulletins Interior - Buzz/Rattle From Front/Rear Door panels NUMBER: 23-009-07 GROUP: Body DATE: March 20, 2007 SUBJECT: Radio Speaker Misdiagnosis - Rattle/Buzz Sounds in Door Modules OVERVIEW: This bulletin involves removing the Bolster and Door Panel Modules and applying foam tape at critical points of wiring, actuator rods, panel connection points and the side Instrument Panel end caps. PARTS REQUIRED: MODELS: 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber SYMPTOM/CONDITION: Rattle or Buzz like sounds in the door module area, (front or rear). This is most noticeable with the radio on during high volume/deep base settings and is most likely caused by door links or wiring vibrating in the door module. The door module rattle or buzz sounds will not be heard with the radio off. Several areas of concern are involved and if the vehicle operator complains of rattles or buzz noises, perform the following Repair Procedure on ALL doors and both ends of Instrument Panel before replacing speakers. DIAGNOSIS: If the symptom/condition is present, perform the Repair Procedure. FRONT DOOR REPAIR PROCEDURE: 1. Lower the front windows: a. MK: 89 mm (3.5 in.) b. PM: 102 mm (4 in.) 2.5GLower the rear windows 152 mm (6 in.), (Preparing for rear door Repair Procedure). 3. Disconnect and isolate negative battery cable. 4. Pull weatherstrip off front of door at wire harness door bracket entering door. Remove 2 bolts, (5 mm hex), at retaining plate. Disconnect wire harness from body of vehicle. Pull wiring from behind weatherstrip. 5. Remove trim cap and screw, (T-20 Torx), at inside door handle. 6. Remove manual window crank handle, (if equipped). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > 23-009-07 > Mar > 07 > Interior - Buzz/Rattle From Front/Rear Door panels > Page 8830 7. Remove interior trim flag for outside mirror, disconnect wire harness to electric mirror, (if equipped). 8. Using trim stick, remove speaker cover. 9. Remove top front and lower rear speaker screws only, (T-20 Torx). (Speaker will stay with door module). 10. Remove bolt(s), (10 mm hex), retaining door module near speaker: a. MK: 2 bolts. b. PM: 1 bolt. 11. Remove (2) longer bolts, (10 mm hex), retaining door module at bottom of door module. 12. Remove trim cap and screw, (T-20 Torx), at inside door pull cup. 13. Using trim stick, release bolster, swing down and allow to hang by tethers. 14. Release both window latches on regulator, pull up and roll back of window up to remove from door from the outside of door. Set glass aside on protected surface. 15. Remove bolts, (10 mm hex), behind bolster, (2 in regulators and 1 at center of door module). 16. Disconnect linkages at door latch to: a. Outside door handle, (both sides of vehicle). b. Lock cylinder, (drivers side only). 17. Remove (3) screws, (T-30 Torx), retaining latch to door. 18. Maneuver door module up, then forward, then down to remove from door. 19. Place removed door module face down on a clean, protected surface. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > 23-009-07 > Mar > 07 > Interior - Buzz/Rattle From Front/Rear Door panels > Page 8831 20. Remove wiring and convolute tubing from retainers and wrap with Open Cell Foam Tape, (p/n 05019057AA), in the areas described in below. Any wiring or convoluted tubing that is not wrapped or can come in contact with the door module shell should be wrapped with foam tape as shown in (Fig. 1) for MK and (Fig. 2) for PM. Reinstall wiring and convolute tubing in retainers. 21. Follow specific instructions based on vehicle below: a. MK: Cut the Closed Cell Low Density Foam Tape, (p/n 05019058AA) into 25 mm (1 in.) lengths and stack, (if needed), to back up actuator rods as shown in (Fig. 1), above. Place a piece of Itch and Squeak Tape, (p/n 05019054AA) on the top layer of Closed Cell Low Density Foam Tape where it contacts actuator rod. b. PM: Cut the Closed Cell Low Density Foam Tape, (p/n 05019058AA) into 12 mm (.5 in.) length to back up actuator rod as shown in (Fig. 3) below. NOTE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > 23-009-07 > Mar > 07 > Interior - Buzz/Rattle From Front/Rear Door panels > Page 8832 Actuator rod is removed and pulled from stay for easy installation 22. Turn door module over, (face up) and cut 6 lengths of Open Cell Foam Tape, (p/n 05019057AA) into 6.5 mm (.25 in.) strips lengthwise. Install on door bolster TOP and BOTTOM horizontal surfaces on the smooth surface where it meets door module opening. Start at the forward most section of the bolster to the rear most area of the horizontal surface isolating the Bolster from the mating surface of the door Panel Module. See (Fig. 4) below. Bottom of Bolster is shown, Top is similar. 23. Loosely install the lower bolt(s), (10 mm hex), for window regulator in bottom of door module. Thread bolt(s) into door module so that threads protrude through module about 12 mm, (.5 in.) then start threads into bottom of regulator. Bolt should now be threaded into door module and regulator with a space in between regulator and door module. Be sure window regulator guide tab is in proper position in door module. 24. Position door module in door shell making sure to slip wiring to body, (at front of door), behind weather-strip and guide window regulators and door latch mechanisms in place inside door shell. 25. Align top of door module in position and slide down in place. Lower window regulator bolts installed earlier in step Step # 23 should slide in "V" notch(s) in bottom of door with regulators inside door shell. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > 23-009-07 > Mar > 07 > Interior - Buzz/Rattle From Front/Rear Door panels > Page 8833 NOTE: Be sure mirror wiring protrudes through opening in top of door module. 26. Start, (do not tighten), all remaining bolts for door module and window regulators. Once all bolts are loosely installed, tighten all bolts to 8 N.m (71 in. lbs.) 27. Install door latch screws, (T-30 Torx), Tighten to 7 N.m (62 in. lbs.). 28. Connect linkage(s) to door latch mechanism. 29. Position wire harness door bracket at front of door and install screws, (5 mm hex). Install weatherstrip. 30. Connect wire harness to body from door. 31. Connect mirror wire harness, (if equipped) and install trim flag. 32. Install screw, (T-20 Torx), at inner door handle and replace trim. 33. Install door glass making sure glass clips into regulator securely. 34. Install door bolster trim panel. 35. Install screw, (T-20 Torx), and trim cap at door pull cup. 36. Install manual window crank handle, (if equipped). 37. Install speaker screws, (T-20 Torx), and speaker grille. 38. Clean glass. 39. Repeat this process for other front door. REAR DOOR REPAIR PROCEDURE: 1. Pull weatherstrip off front of door at wire harness bracket entering door. Remove 2 bolts, (5 mm hex) at wire harness door bracket. Disconnect wire harness from body of vehicle. 2. Remove trim cap and screw, (T-20 Torx), at inside door handle. 3. Remove manual window crank handle, (if equipped). 4. Using trim stick, remove speaker cover. 5. Remove top front and lower rear speaker screws only. (Speaker will remain with door module). 6. Remove bolt(s), (10 mm hex), retaining door module near speaker. a. MK: 2 bolts b. PM: 1 bolt 7. Remove (1) longer bolt, (10 mm hex), retaining door module and window regulator at bottom of door module. 8. Remove trim cap and screw, (1-20 Torx), at inside door pull cup. 9. Using trim stick, release bolster, swing down and allow to hang by tethers. 10. Release window latch retainer at bottom of glass from regulator. 11. Slide glass up in frame and duct tape from outside of window, up over frame to inside of window in the full UP position. 12. Remove bolts, (10 mm hex) behind bolster: a. MK: 2 in regulator and 1 at center of door module. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > 23-009-07 > Mar > 07 > Interior - Buzz/Rattle From Front/Rear Door panels > Page 8834 b. PM: 1 in regulator, 2 in window motor brace and 1 in door module. 13. Disconnect linkage(s) at latch to: a. MK49 - Compass 1). Outside door handle and 2). Fulcrum. b. MK74 - Patriot and PM - Caliber Outside door handle. 14. Remove (3) screws, (T-30 Torx), retaining latch to door. 15. Maneuver door module up, then forward, then down to remove from door. 16. Place removed door module face down on a clean, protected surface. 17. Follow specific instructions based on vehicle below: a. MK: Remove wiring and convolute tubing from retainers and wrap with Open Cell Foam Tape, (p/n 05019057AA) in the areas described in below. Any wiring or convoluted tubing that is not wrapped or can come in contact with the door module shell should be wrapped with foam tape as shown in (Fig. 6) below. Reinstall wiring and convolute tubing back in retainers. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > 23-009-07 > Mar > 07 > Interior - Buzz/Rattle From Front/Rear Door panels > Page 8835 b. PM: Remove wiring and convolute tubing from retainers and wrap with Open Cell Foam Tape, (p/n 05019057AA) in the areas described in below. Any wiring or convoluted tubing that is not wrapped or can come in contact with the door module shell should be wrapped with foam tape as shown in (Fig. 7) below. Reinstall wiring and convolute tubing back in retainers. 18. Cut the Closed Cell Low Density Foam Tape, (p/n 05019058AA) into 1" lengths and stack (if needed) to back up actuator rods with Itch and Squeak Tape, (p/n 05019054AA) as top layer, as shown in (Fig. 8) below. NOTE: If # 2 below is not existing, install it. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > 23-009-07 > Mar > 07 > Interior - Buzz/Rattle From Front/Rear Door panels > Page 8836 19. Follow specific instructions based on vehicle below: a. MK: cut 12 mm (.5 in) Open Cell Foam Tape, (p/n 05019057AA) and put at top rear corner of door module as shown in (Fig. 9) below. Do not allow Foam Tape to protrude past outside edge of door module. b. PM: cut 1.5 in Closed Cell Low Density Foam Tape, (p/n 05019058AA) and put at top rear corner of door module, inside outer lip as shown in (Fig. 10) below. Do not allow Foam Tape to protrude past outside edge of door module. 20. Turn door module over, (face up) and cut 6 lengths of Open Cell Foam Tape, (p/n 05019057AA) into 6.5 mm (.25 in.) strips lengthwise. Install on door bolster TOP and BOTTOM horizontal surfaces on the smooth surface where it meets door module opening. Start at the forward most section of the bolster to the rear most area of the horizontal surface isolating the Bolster from the mating surface of the door Panel Module. See (Fig. 4) above for front door. 21. Loosely install the longer bolt, (10 mm hex), for window regulator in bottom of door module. Thread bolt into door module so that threads protrude through module about 9.5 mm, (.375 in) then start threads into bottom of regulator. Bolt should now be threaded into door module and regulator with a space in between regulator and door module, similar to (Fig. 5) above. Be sure window regulator guide tab is in proper position in door module. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > 23-009-07 > Mar > 07 > Interior - Buzz/Rattle From Front/Rear Door panels > Page 8837 22. Position door module in door shell making sure to slip wiring to body, (at front of door), behind weatherstrip and guide window regulator and door latch mechanisms in place inside door shell. 23. Align top of door module in position and slide down in place. Lower window regulator bolt installed earlier in step Step # 21 should slide in "V" notch in bottom of door with regulator inside door shell. 24. Start, (do not tighten), all remaining bolts, (10 mm hex), for door module and window regulator. Tighten all bolts to 8 N.m (71 in. lbs.) 25. Install door latch screws, (T-30 Torx), Tighten to 7 N.m (62 in. lbs.). 26. Connect linkage(s) to door latch mechanism. 27. Position wire harness door bracket at front of door and install screws, (5 mm hex). Install weatherstrip. 28. Connect wire harness to body from door. 29. Install screw, (T-20 Torx), at inner door handle and replace trim. 30. Remove previously installed tape from door glass and slide door glass down making sure glass clips into regulator securely. 31. Install door bolster trim panel. 32. Install screw, (T-20 Torx), and trim cap at door pull cup. 33. Install manual window crank handle, (if equipped). 34. Install speaker screws and speaker grille. 35. Clean glass. 36. Repeat this process for other rear door. INSTRUMENT PANEL END CAP REPAIR PROCEDURE: 1. Loosen weatherstrip along front edge of instrument panel end cap. 2. Remove instrument panel end cap. 3. Cut 8 (.5 in.) pieces, (4 for each side) of Open Cell Foam Tape, (p/n 05019057AA). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > 23-009-07 > Mar > 07 > Interior - Buzz/Rattle From Front/Rear Door panels > Page 8838 4. Install 4 pieces of Open Cell Foam Tape at the mating surface for the cover as shown in # 1 (Fig. 11) below. 5. Cut 6 square pieces, (3 for each side) of Closed Cell Low Density Foam Tape, (p/n 05019058AA). 6. Stack 3 pieces of Closed Cell Low Density Foam Tape and cover top layer with Itch and Squeak Tape, (pin 05019054AA). Adhere stack towards the center area of cover on the end of the instrument panel as shown in #2 (Fig. 11) below. 7. Replace instrument panel end cover and reposition weatherstrip. 8. Repeat steps (1) through (7) for other side of instrument panel. 9. Reconnect battery negative cable. 10. Check operation of all door related systems, and audio functions. 11. Reset clock for customer satisfaction. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > Page 8839 Rear Door Panel: By Symptom Technical Service Bulletin # 23-009-07 Date: 070320 Interior - Buzz/Rattle From Front/Rear Door panels NUMBER: 23-009-07 GROUP: Body DATE: March 20, 2007 SUBJECT: Radio Speaker Misdiagnosis - Rattle/Buzz Sounds in Door Modules OVERVIEW: This bulletin involves removing the Bolster and Door Panel Modules and applying foam tape at critical points of wiring, actuator rods, panel connection points and the side Instrument Panel end caps. PARTS REQUIRED: MODELS: 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber SYMPTOM/CONDITION: Rattle or Buzz like sounds in the door module area, (front or rear). This is most noticeable with the radio on during high volume/deep base settings and is most likely caused by door links or wiring vibrating in the door module. The door module rattle or buzz sounds will not be heard with the radio off. Several areas of concern are involved and if the vehicle operator complains of rattles or buzz noises, perform the following Repair Procedure on ALL doors and both ends of Instrument Panel before replacing speakers. DIAGNOSIS: If the symptom/condition is present, perform the Repair Procedure. FRONT DOOR REPAIR PROCEDURE: 1. Lower the front windows: a. MK: 89 mm (3.5 in.) b. PM: 102 mm (4 in.) 2.5GLower the rear windows 152 mm (6 in.), (Preparing for rear door Repair Procedure). 3. Disconnect and isolate negative battery cable. 4. Pull weatherstrip off front of door at wire harness door bracket entering door. Remove 2 bolts, (5 mm hex), at retaining plate. Disconnect wire harness from body of vehicle. Pull wiring from behind weatherstrip. 5. Remove trim cap and screw, (T-20 Torx), at inside door handle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > Page 8840 6. Remove manual window crank handle, (if equipped). 7. Remove interior trim flag for outside mirror, disconnect wire harness to electric mirror, (if equipped). 8. Using trim stick, remove speaker cover. 9. Remove top front and lower rear speaker screws only, (T-20 Torx). (Speaker will stay with door module). 10. Remove bolt(s), (10 mm hex), retaining door module near speaker: a. MK: 2 bolts. b. PM: 1 bolt. 11. Remove (2) longer bolts, (10 mm hex), retaining door module at bottom of door module. 12. Remove trim cap and screw, (T-20 Torx), at inside door pull cup. 13. Using trim stick, release bolster, swing down and allow to hang by tethers. 14. Release both window latches on regulator, pull up and roll back of window up to remove from door from the outside of door. Set glass aside on protected surface. 15. Remove bolts, (10 mm hex), behind bolster, (2 in regulators and 1 at center of door module). 16. Disconnect linkages at door latch to: a. Outside door handle, (both sides of vehicle). b. Lock cylinder, (drivers side only). 17. Remove (3) screws, (T-30 Torx), retaining latch to door. 18. Maneuver door module up, then forward, then down to remove from door. 19. Place removed door module face down on a clean, protected surface. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > Page 8841 20. Remove wiring and convolute tubing from retainers and wrap with Open Cell Foam Tape, (p/n 05019057AA), in the areas described in below. Any wiring or convoluted tubing that is not wrapped or can come in contact with the door module shell should be wrapped with foam tape as shown in (Fig. 1) for MK and (Fig. 2) for PM. Reinstall wiring and convolute tubing in retainers. 21. Follow specific instructions based on vehicle below: a. MK: Cut the Closed Cell Low Density Foam Tape, (p/n 05019058AA) into 25 mm (1 in.) lengths and stack, (if needed), to back up actuator rods as shown in (Fig. 1), above. Place a piece of Itch and Squeak Tape, (p/n 05019054AA) on the top layer of Closed Cell Low Density Foam Tape where it contacts actuator rod. b. PM: Cut the Closed Cell Low Density Foam Tape, (p/n 05019058AA) into 12 mm (.5 in.) length to back up actuator rod as shown in (Fig. 3) below. NOTE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > Page 8842 Actuator rod is removed and pulled from stay for easy installation 22. Turn door module over, (face up) and cut 6 lengths of Open Cell Foam Tape, (p/n 05019057AA) into 6.5 mm (.25 in.) strips lengthwise. Install on door bolster TOP and BOTTOM horizontal surfaces on the smooth surface where it meets door module opening. Start at the forward most section of the bolster to the rear most area of the horizontal surface isolating the Bolster from the mating surface of the door Panel Module. See (Fig. 4) below. Bottom of Bolster is shown, Top is similar. 23. Loosely install the lower bolt(s), (10 mm hex), for window regulator in bottom of door module. Thread bolt(s) into door module so that threads protrude through module about 12 mm, (.5 in.) then start threads into bottom of regulator. Bolt should now be threaded into door module and regulator with a space in between regulator and door module. Be sure window regulator guide tab is in proper position in door module. 24. Position door module in door shell making sure to slip wiring to body, (at front of door), behind weather-strip and guide window regulators and door latch mechanisms in place inside door shell. 25. Align top of door module in position and slide down in place. Lower window regulator bolts installed earlier in step Step # 23 should slide in "V" notch(s) in bottom of door with regulators inside door shell. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > Page 8843 NOTE: Be sure mirror wiring protrudes through opening in top of door module. 26. Start, (do not tighten), all remaining bolts for door module and window regulators. Once all bolts are loosely installed, tighten all bolts to 8 N.m (71 in. lbs.) 27. Install door latch screws, (T-30 Torx), Tighten to 7 N.m (62 in. lbs.). 28. Connect linkage(s) to door latch mechanism. 29. Position wire harness door bracket at front of door and install screws, (5 mm hex). Install weatherstrip. 30. Connect wire harness to body from door. 31. Connect mirror wire harness, (if equipped) and install trim flag. 32. Install screw, (T-20 Torx), at inner door handle and replace trim. 33. Install door glass making sure glass clips into regulator securely. 34. Install door bolster trim panel. 35. Install screw, (T-20 Torx), and trim cap at door pull cup. 36. Install manual window crank handle, (if equipped). 37. Install speaker screws, (T-20 Torx), and speaker grille. 38. Clean glass. 39. Repeat this process for other front door. REAR DOOR REPAIR PROCEDURE: 1. Pull weatherstrip off front of door at wire harness bracket entering door. Remove 2 bolts, (5 mm hex) at wire harness door bracket. Disconnect wire harness from body of vehicle. 2. Remove trim cap and screw, (T-20 Torx), at inside door handle. 3. Remove manual window crank handle, (if equipped). 4. Using trim stick, remove speaker cover. 5. Remove top front and lower rear speaker screws only. (Speaker will remain with door module). 6. Remove bolt(s), (10 mm hex), retaining door module near speaker. a. MK: 2 bolts b. PM: 1 bolt 7. Remove (1) longer bolt, (10 mm hex), retaining door module and window regulator at bottom of door module. 8. Remove trim cap and screw, (1-20 Torx), at inside door pull cup. 9. Using trim stick, release bolster, swing down and allow to hang by tethers. 10. Release window latch retainer at bottom of glass from regulator. 11. Slide glass up in frame and duct tape from outside of window, up over frame to inside of window in the full UP position. 12. Remove bolts, (10 mm hex) behind bolster: a. MK: 2 in regulator and 1 at center of door module. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > Page 8844 b. PM: 1 in regulator, 2 in window motor brace and 1 in door module. 13. Disconnect linkage(s) at latch to: a. MK49 - Compass 1). Outside door handle and 2). Fulcrum. b. MK74 - Patriot and PM - Caliber Outside door handle. 14. Remove (3) screws, (T-30 Torx), retaining latch to door. 15. Maneuver door module up, then forward, then down to remove from door. 16. Place removed door module face down on a clean, protected surface. 17. Follow specific instructions based on vehicle below: a. MK: Remove wiring and convolute tubing from retainers and wrap with Open Cell Foam Tape, (p/n 05019057AA) in the areas described in below. Any wiring or convoluted tubing that is not wrapped or can come in contact with the door module shell should be wrapped with foam tape as shown in (Fig. 6) below. Reinstall wiring and convolute tubing back in retainers. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > Page 8845 b. PM: Remove wiring and convolute tubing from retainers and wrap with Open Cell Foam Tape, (p/n 05019057AA) in the areas described in below. Any wiring or convoluted tubing that is not wrapped or can come in contact with the door module shell should be wrapped with foam tape as shown in (Fig. 7) below. Reinstall wiring and convolute tubing back in retainers. 18. Cut the Closed Cell Low Density Foam Tape, (p/n 05019058AA) into 1" lengths and stack (if needed) to back up actuator rods with Itch and Squeak Tape, (p/n 05019054AA) as top layer, as shown in (Fig. 8) below. NOTE: If # 2 below is not existing, install it. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > Page 8846 19. Follow specific instructions based on vehicle below: a. MK: cut 12 mm (.5 in) Open Cell Foam Tape, (p/n 05019057AA) and put at top rear corner of door module as shown in (Fig. 9) below. Do not allow Foam Tape to protrude past outside edge of door module. b. PM: cut 1.5 in Closed Cell Low Density Foam Tape, (p/n 05019058AA) and put at top rear corner of door module, inside outer lip as shown in (Fig. 10) below. Do not allow Foam Tape to protrude past outside edge of door module. 20. Turn door module over, (face up) and cut 6 lengths of Open Cell Foam Tape, (p/n 05019057AA) into 6.5 mm (.25 in.) strips lengthwise. Install on door bolster TOP and BOTTOM horizontal surfaces on the smooth surface where it meets door module opening. Start at the forward most section of the bolster to the rear most area of the horizontal surface isolating the Bolster from the mating surface of the door Panel Module. See (Fig. 4) above for front door. 21. Loosely install the longer bolt, (10 mm hex), for window regulator in bottom of door module. Thread bolt into door module so that threads protrude through module about 9.5 mm, (.375 in) then start threads into bottom of regulator. Bolt should now be threaded into door module and regulator with a space in between regulator and door module, similar to (Fig. 5) above. Be sure window regulator guide tab is in proper position in door module. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > Page 8847 22. Position door module in door shell making sure to slip wiring to body, (at front of door), behind weatherstrip and guide window regulator and door latch mechanisms in place inside door shell. 23. Align top of door module in position and slide down in place. Lower window regulator bolt installed earlier in step Step # 21 should slide in "V" notch in bottom of door with regulator inside door shell. 24. Start, (do not tighten), all remaining bolts, (10 mm hex), for door module and window regulator. Tighten all bolts to 8 N.m (71 in. lbs.) 25. Install door latch screws, (T-30 Torx), Tighten to 7 N.m (62 in. lbs.). 26. Connect linkage(s) to door latch mechanism. 27. Position wire harness door bracket at front of door and install screws, (5 mm hex). Install weatherstrip. 28. Connect wire harness to body from door. 29. Install screw, (T-20 Torx), at inner door handle and replace trim. 30. Remove previously installed tape from door glass and slide door glass down making sure glass clips into regulator securely. 31. Install door bolster trim panel. 32. Install screw, (T-20 Torx), and trim cap at door pull cup. 33. Install manual window crank handle, (if equipped). 34. Install speaker screws and speaker grille. 35. Clean glass. 36. Repeat this process for other rear door. INSTRUMENT PANEL END CAP REPAIR PROCEDURE: 1. Loosen weatherstrip along front edge of instrument panel end cap. 2. Remove instrument panel end cap. 3. Cut 8 (.5 in.) pieces, (4 for each side) of Open Cell Foam Tape, (p/n 05019057AA). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > Page 8848 4. Install 4 pieces of Open Cell Foam Tape at the mating surface for the cover as shown in # 1 (Fig. 11) below. 5. Cut 6 square pieces, (3 for each side) of Closed Cell Low Density Foam Tape, (p/n 05019058AA). 6. Stack 3 pieces of Closed Cell Low Density Foam Tape and cover top layer with Itch and Squeak Tape, (pin 05019054AA). Adhere stack towards the center area of cover on the end of the instrument panel as shown in #2 (Fig. 11) below. 7. Replace instrument panel end cover and reposition weatherstrip. 8. Repeat steps (1) through (7) for other side of instrument panel. 9. Reconnect battery negative cable. 10. Check operation of all door related systems, and audio functions. 11. Reset clock for customer satisfaction. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 23-009-07 Date: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > Page 8849 070320 Interior - Buzz/Rattle From Front/Rear Door panels NUMBER: 23-009-07 GROUP: Body DATE: March 20, 2007 SUBJECT: Radio Speaker Misdiagnosis - Rattle/Buzz Sounds in Door Modules OVERVIEW: This bulletin involves removing the Bolster and Door Panel Modules and applying foam tape at critical points of wiring, actuator rods, panel connection points and the side Instrument Panel end caps. PARTS REQUIRED: MODELS: 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber SYMPTOM/CONDITION: Rattle or Buzz like sounds in the door module area, (front or rear). This is most noticeable with the radio on during high volume/deep base settings and is most likely caused by door links or wiring vibrating in the door module. The door module rattle or buzz sounds will not be heard with the radio off. Several areas of concern are involved and if the vehicle operator complains of rattles or buzz noises, perform the following Repair Procedure on ALL doors and both ends of Instrument Panel before replacing speakers. DIAGNOSIS: If the symptom/condition is present, perform the Repair Procedure. FRONT DOOR REPAIR PROCEDURE: 1. Lower the front windows: a. MK: 89 mm (3.5 in.) b. PM: 102 mm (4 in.) 2.5GLower the rear windows 152 mm (6 in.), (Preparing for rear door Repair Procedure). 3. Disconnect and isolate negative battery cable. 4. Pull weatherstrip off front of door at wire harness door bracket entering door. Remove 2 bolts, (5 mm hex), at retaining plate. Disconnect wire harness from body of vehicle. Pull wiring from behind weatherstrip. 5. Remove trim cap and screw, (T-20 Torx), at inside door handle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > Page 8850 6. Remove manual window crank handle, (if equipped). 7. Remove interior trim flag for outside mirror, disconnect wire harness to electric mirror, (if equipped). 8. Using trim stick, remove speaker cover. 9. Remove top front and lower rear speaker screws only, (T-20 Torx). (Speaker will stay with door module). 10. Remove bolt(s), (10 mm hex), retaining door module near speaker: a. MK: 2 bolts. b. PM: 1 bolt. 11. Remove (2) longer bolts, (10 mm hex), retaining door module at bottom of door module. 12. Remove trim cap and screw, (T-20 Torx), at inside door pull cup. 13. Using trim stick, release bolster, swing down and allow to hang by tethers. 14. Release both window latches on regulator, pull up and roll back of window up to remove from door from the outside of door. Set glass aside on protected surface. 15. Remove bolts, (10 mm hex), behind bolster, (2 in regulators and 1 at center of door module). 16. Disconnect linkages at door latch to: a. Outside door handle, (both sides of vehicle). b. Lock cylinder, (drivers side only). 17. Remove (3) screws, (T-30 Torx), retaining latch to door. 18. Maneuver door module up, then forward, then down to remove from door. 19. Place removed door module face down on a clean, protected surface. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > Page 8851 20. Remove wiring and convolute tubing from retainers and wrap with Open Cell Foam Tape, (p/n 05019057AA), in the areas described in below. Any wiring or convoluted tubing that is not wrapped or can come in contact with the door module shell should be wrapped with foam tape as shown in (Fig. 1) for MK and (Fig. 2) for PM. Reinstall wiring and convolute tubing in retainers. 21. Follow specific instructions based on vehicle below: a. MK: Cut the Closed Cell Low Density Foam Tape, (p/n 05019058AA) into 25 mm (1 in.) lengths and stack, (if needed), to back up actuator rods as shown in (Fig. 1), above. Place a piece of Itch and Squeak Tape, (p/n 05019054AA) on the top layer of Closed Cell Low Density Foam Tape where it contacts actuator rod. b. PM: Cut the Closed Cell Low Density Foam Tape, (p/n 05019058AA) into 12 mm (.5 in.) length to back up actuator rod as shown in (Fig. 3) below. NOTE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > Page 8852 Actuator rod is removed and pulled from stay for easy installation 22. Turn door module over, (face up) and cut 6 lengths of Open Cell Foam Tape, (p/n 05019057AA) into 6.5 mm (.25 in.) strips lengthwise. Install on door bolster TOP and BOTTOM horizontal surfaces on the smooth surface where it meets door module opening. Start at the forward most section of the bolster to the rear most area of the horizontal surface isolating the Bolster from the mating surface of the door Panel Module. See (Fig. 4) below. Bottom of Bolster is shown, Top is similar. 23. Loosely install the lower bolt(s), (10 mm hex), for window regulator in bottom of door module. Thread bolt(s) into door module so that threads protrude through module about 12 mm, (.5 in.) then start threads into bottom of regulator. Bolt should now be threaded into door module and regulator with a space in between regulator and door module. Be sure window regulator guide tab is in proper position in door module. 24. Position door module in door shell making sure to slip wiring to body, (at front of door), behind weather-strip and guide window regulators and door latch mechanisms in place inside door shell. 25. Align top of door module in position and slide down in place. Lower window regulator bolts installed earlier in step Step # 23 should slide in "V" notch(s) in bottom of door with regulators inside door shell. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > Page 8853 NOTE: Be sure mirror wiring protrudes through opening in top of door module. 26. Start, (do not tighten), all remaining bolts for door module and window regulators. Once all bolts are loosely installed, tighten all bolts to 8 N.m (71 in. lbs.) 27. Install door latch screws, (T-30 Torx), Tighten to 7 N.m (62 in. lbs.). 28. Connect linkage(s) to door latch mechanism. 29. Position wire harness door bracket at front of door and install screws, (5 mm hex). Install weatherstrip. 30. Connect wire harness to body from door. 31. Connect mirror wire harness, (if equipped) and install trim flag. 32. Install screw, (T-20 Torx), at inner door handle and replace trim. 33. Install door glass making sure glass clips into regulator securely. 34. Install door bolster trim panel. 35. Install screw, (T-20 Torx), and trim cap at door pull cup. 36. Install manual window crank handle, (if equipped). 37. Install speaker screws, (T-20 Torx), and speaker grille. 38. Clean glass. 39. Repeat this process for other front door. REAR DOOR REPAIR PROCEDURE: 1. Pull weatherstrip off front of door at wire harness bracket entering door. Remove 2 bolts, (5 mm hex) at wire harness door bracket. Disconnect wire harness from body of vehicle. 2. Remove trim cap and screw, (T-20 Torx), at inside door handle. 3. Remove manual window crank handle, (if equipped). 4. Using trim stick, remove speaker cover. 5. Remove top front and lower rear speaker screws only. (Speaker will remain with door module). 6. Remove bolt(s), (10 mm hex), retaining door module near speaker. a. MK: 2 bolts b. PM: 1 bolt 7. Remove (1) longer bolt, (10 mm hex), retaining door module and window regulator at bottom of door module. 8. Remove trim cap and screw, (1-20 Torx), at inside door pull cup. 9. Using trim stick, release bolster, swing down and allow to hang by tethers. 10. Release window latch retainer at bottom of glass from regulator. 11. Slide glass up in frame and duct tape from outside of window, up over frame to inside of window in the full UP position. 12. Remove bolts, (10 mm hex) behind bolster: a. MK: 2 in regulator and 1 at center of door module. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > Page 8854 b. PM: 1 in regulator, 2 in window motor brace and 1 in door module. 13. Disconnect linkage(s) at latch to: a. MK49 - Compass 1). Outside door handle and 2). Fulcrum. b. MK74 - Patriot and PM - Caliber Outside door handle. 14. Remove (3) screws, (T-30 Torx), retaining latch to door. 15. Maneuver door module up, then forward, then down to remove from door. 16. Place removed door module face down on a clean, protected surface. 17. Follow specific instructions based on vehicle below: a. MK: Remove wiring and convolute tubing from retainers and wrap with Open Cell Foam Tape, (p/n 05019057AA) in the areas described in below. Any wiring or convoluted tubing that is not wrapped or can come in contact with the door module shell should be wrapped with foam tape as shown in (Fig. 6) below. Reinstall wiring and convolute tubing back in retainers. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > Page 8855 b. PM: Remove wiring and convolute tubing from retainers and wrap with Open Cell Foam Tape, (p/n 05019057AA) in the areas described in below. Any wiring or convoluted tubing that is not wrapped or can come in contact with the door module shell should be wrapped with foam tape as shown in (Fig. 7) below. Reinstall wiring and convolute tubing back in retainers. 18. Cut the Closed Cell Low Density Foam Tape, (p/n 05019058AA) into 1" lengths and stack (if needed) to back up actuator rods with Itch and Squeak Tape, (p/n 05019054AA) as top layer, as shown in (Fig. 8) below. NOTE: If # 2 below is not existing, install it. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > Page 8856 19. Follow specific instructions based on vehicle below: a. MK: cut 12 mm (.5 in) Open Cell Foam Tape, (p/n 05019057AA) and put at top rear corner of door module as shown in (Fig. 9) below. Do not allow Foam Tape to protrude past outside edge of door module. b. PM: cut 1.5 in Closed Cell Low Density Foam Tape, (p/n 05019058AA) and put at top rear corner of door module, inside outer lip as shown in (Fig. 10) below. Do not allow Foam Tape to protrude past outside edge of door module. 20. Turn door module over, (face up) and cut 6 lengths of Open Cell Foam Tape, (p/n 05019057AA) into 6.5 mm (.25 in.) strips lengthwise. Install on door bolster TOP and BOTTOM horizontal surfaces on the smooth surface where it meets door module opening. Start at the forward most section of the bolster to the rear most area of the horizontal surface isolating the Bolster from the mating surface of the door Panel Module. See (Fig. 4) above for front door. 21. Loosely install the longer bolt, (10 mm hex), for window regulator in bottom of door module. Thread bolt into door module so that threads protrude through module about 9.5 mm, (.375 in) then start threads into bottom of regulator. Bolt should now be threaded into door module and regulator with a space in between regulator and door module, similar to (Fig. 5) above. Be sure window regulator guide tab is in proper position in door module. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > Page 8857 22. Position door module in door shell making sure to slip wiring to body, (at front of door), behind weatherstrip and guide window regulator and door latch mechanisms in place inside door shell. 23. Align top of door module in position and slide down in place. Lower window regulator bolt installed earlier in step Step # 21 should slide in "V" notch in bottom of door with regulator inside door shell. 24. Start, (do not tighten), all remaining bolts, (10 mm hex), for door module and window regulator. Tighten all bolts to 8 N.m (71 in. lbs.) 25. Install door latch screws, (T-30 Torx), Tighten to 7 N.m (62 in. lbs.). 26. Connect linkage(s) to door latch mechanism. 27. Position wire harness door bracket at front of door and install screws, (5 mm hex). Install weatherstrip. 28. Connect wire harness to body from door. 29. Install screw, (T-20 Torx), at inner door handle and replace trim. 30. Remove previously installed tape from door glass and slide door glass down making sure glass clips into regulator securely. 31. Install door bolster trim panel. 32. Install screw, (T-20 Torx), and trim cap at door pull cup. 33. Install manual window crank handle, (if equipped). 34. Install speaker screws and speaker grille. 35. Clean glass. 36. Repeat this process for other rear door. INSTRUMENT PANEL END CAP REPAIR PROCEDURE: 1. Loosen weatherstrip along front edge of instrument panel end cap. 2. Remove instrument panel end cap. 3. Cut 8 (.5 in.) pieces, (4 for each side) of Open Cell Foam Tape, (p/n 05019057AA). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > Page 8858 4. Install 4 pieces of Open Cell Foam Tape at the mating surface for the cover as shown in # 1 (Fig. 11) below. 5. Cut 6 square pieces, (3 for each side) of Closed Cell Low Density Foam Tape, (p/n 05019058AA). 6. Stack 3 pieces of Closed Cell Low Density Foam Tape and cover top layer with Itch and Squeak Tape, (pin 05019054AA). Adhere stack towards the center area of cover on the end of the instrument panel as shown in #2 (Fig. 11) below. 7. Replace instrument panel end cover and reposition weatherstrip. 8. Repeat steps (1) through (7) for other side of instrument panel. 9. Reconnect battery negative cable. 10. Check operation of all door related systems, and audio functions. 11. Reset clock for customer satisfaction. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Door-Plugs Rear Door Panel: Service and Repair Door-Plugs Removal REMOVAL 1. Using special tool C-4755, pry up handle plug (3) from door (1). 2. Using special tool C-4755, pry up speaker grille (4) from door. Installation INSTALLATION 1. Align speaker grille (4) with speaker opening and hand tap speaker grille (4) to door ensuring fit. 2. Align handle plug with handle plug opening and hand tap ensuring fit. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Door-Plugs > Page 8861 Rear Door Panel: Service and Repair Speaker And Grille Removal REMOVAL 1. Using trim stick C-4755, find service notch (1) located at the bottom of speaker grille and pry up speaker grille. 2. Remove two screws attaching speaker to door panel (3). 3. Remove two screws attaching speaker (2) to door module (1). 4. Disconnect wire connector. Installation INSTALLATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Door-Plugs > Page 8862 1. Place speaker (2) up to door module (3). 2. Connect wire connector. 3. Install screws fastening speaker to door module. 4. Place speaker grille (1) up to door module and install fasteners. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Door-Plugs > Page 8863 Rear Door Panel: Service and Repair Rear Door - Bolster Removal REMOVAL 1. Remove screw (1) from pull cup. 2. If equipped, remove window crank (4) and washer (5) from bolster (3). 3. Using trim stick C-4755, unsnap bolster from door panel. 4. If equipped, disconnect wire connector from window switch. Installation INSTALLATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Door-Plugs > Page 8864 1. Connect wire harness (7) to window switch connector (4). 2. Align bolster (3) with door and hand tap bolster to door ensuring fit. 3. Insert screw (1) into pull cup and tighten. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Service and Repair > Removal Rear Door Striker: Service and Repair Removal REMOVAL 1. Open door. 2. Remove fasteners (2). 3. Remove striker (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Service and Repair > Removal > Page 8869 Rear Door Striker: Service and Repair Installation INSTALLATION 1. Align striker (1) with holes in body. 2. Install fasteners. 3. Tighten fasteners to 26 Nm (19 ft. lbs.) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > System Information > Service and Repair > Removal Rear Door Window Glass: Service and Repair Removal REMOVAL 1. Remove speaker and grille. 2. Remove bolster. 3. Remove door module. 4. Raise window (5) gaining access to window tabs. 5. With a punch or equivalent, press regulator tabs holding window in regulator (3). 6. Carefully, remove window (5). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > System Information > Service and Repair > Removal > Page 8874 Rear Door Window Glass: Service and Repair Installation INSTALLATION 1. Install window regulator to door panel. 2. Install glass (1) down through window channel into window regulator (2) ensuring glass properly seats in access holes. 3. Connect wire connectors. 4. Install door module. 5. Install bolster. 6. Install speaker and grille. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Technical Service Bulletins > Customer Interest for Rear Door Window Regulator: > 23-028-08 > Sep > 08 > Body - Noise When Operating Front/Rear Door Windows Rear Door Window Regulator: Customer Interest Body - Noise When Operating Front/Rear Door Windows NUMBER: 23-028-08 GROUP: Body DATE: September 19, 2008 SUBJECT: Squeak or Groan Sound When Raising or Lowering Door Glass OVERVIEW: This bulletin involves lubricating the window regulator rails. MODELS: 2006 - 2007 (CS) Pacifica 2007 - 2008 (LX) 300/Magnum/Charger 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber NOTE: This bulletin applies to all 2006 - 2007 CS, 2007 - 2008 LX vehicles built before November 14th, 2007 (MDH 1114XX) and PM/MK vehicles built before May 13th 2008 (MDH 0513XX). SYMPTOM/CONDITION: Squeak or squealing sound from window regulator area when raising or lowering front or rear door glass. Groaning sound when cycling front or rear door glass to full up position. DIAGNOSIS: If the customer describes the Symptom/Condition, verify the sound is from the regulator and is not being caused by glass run seals or belt seals. If the condition is present, perform the Repair Procedure on the door. PARTS REQUIRED: REPAIR PROCEDURE - PM/MK: 1. Remove door trim bolster. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > PANEL, Door Trim > Removal > REMOVAL. 2. Remove the door speaker cover and speaker. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 08 - Electrical > 8A - Audio > Speaker > Removal > Removal. 3. Lower regulator to a position where forward (white) slider is visible through opening. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Technical Service Bulletins > Customer Interest for Rear Door Window Regulator: > 23-028-08 > Sep > 08 > Body - Noise When Operating Front/Rear Door Windows > Page 8883 4. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers (Fig 1). 5. Move regulator to position where rear (white) slider is visible through opening. 6. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers (Fig 2). 7. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 8. Install the door speaker and cover. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 08 - Electrical > 8A - Audio > Speaker > Installation > Installation. 9. Install door trim bolster. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 10. Repeat the lubrication process only on doors that have a regulator squeak or groan sound issue. REPAIR PROCEDURE - CS: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Technical Service Bulletins > Customer Interest for Rear Door Window Regulator: > 23-028-08 > Sep > 08 > Body - Noise When Operating Front/Rear Door Windows > Page 8884 1. Remove door trim panel and watershield to access regulator rails and sliders. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Removal > Removal. 2. Lower regulator to a position where forward (white) slider is visible through opening. 3. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 4. Move regulator to position where rear (white) slider is visible through opening. 5. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 6. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 7. Install watershield and door trim panel. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 8. Repeat the lubrication process only on doors that have a regulator squeak or groan issue. REPAIR PROCEDURE - LX: 1. Remove door trim panel and watershield to access regulator rails and sliders. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Removal > Removal. 2. Lower regulator to a position where forward (white) slider is visible through opening. 3. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 4. Move regulator to position where rear (white) slider is visible through opening. 5. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 6. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 7. Install watershield and door trim panel. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 8. Repeat the lubrication process only on doors that have a regulator squeak or groan issue. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Technical Service Bulletins > Customer Interest for Rear Door Window Regulator: > 23-028-08 > Sep > 08 > Body - Noise When Operating Front/Rear Door Windows > Page 8885 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > 23-028-08 > Sep > 08 > Body - Noise When Operating Front/Rear Door Windows Rear Door Window Regulator: All Technical Service Bulletins Body - Noise When Operating Front/Rear Door Windows NUMBER: 23-028-08 GROUP: Body DATE: September 19, 2008 SUBJECT: Squeak or Groan Sound When Raising or Lowering Door Glass OVERVIEW: This bulletin involves lubricating the window regulator rails. MODELS: 2006 - 2007 (CS) Pacifica 2007 - 2008 (LX) 300/Magnum/Charger 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber NOTE: This bulletin applies to all 2006 - 2007 CS, 2007 - 2008 LX vehicles built before November 14th, 2007 (MDH 1114XX) and PM/MK vehicles built before May 13th 2008 (MDH 0513XX). SYMPTOM/CONDITION: Squeak or squealing sound from window regulator area when raising or lowering front or rear door glass. Groaning sound when cycling front or rear door glass to full up position. DIAGNOSIS: If the customer describes the Symptom/Condition, verify the sound is from the regulator and is not being caused by glass run seals or belt seals. If the condition is present, perform the Repair Procedure on the door. PARTS REQUIRED: REPAIR PROCEDURE - PM/MK: 1. Remove door trim bolster. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > PANEL, Door Trim > Removal > REMOVAL. 2. Remove the door speaker cover and speaker. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 08 - Electrical > 8A - Audio > Speaker > Removal > Removal. 3. Lower regulator to a position where forward (white) slider is visible through opening. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > 23-028-08 > Sep > 08 > Body - Noise When Operating Front/Rear Door Windows > Page 8891 4. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers (Fig 1). 5. Move regulator to position where rear (white) slider is visible through opening. 6. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers (Fig 2). 7. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 8. Install the door speaker and cover. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 08 - Electrical > 8A - Audio > Speaker > Installation > Installation. 9. Install door trim bolster. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 10. Repeat the lubrication process only on doors that have a regulator squeak or groan sound issue. REPAIR PROCEDURE - CS: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > 23-028-08 > Sep > 08 > Body - Noise When Operating Front/Rear Door Windows > Page 8892 1. Remove door trim panel and watershield to access regulator rails and sliders. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Removal > Removal. 2. Lower regulator to a position where forward (white) slider is visible through opening. 3. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 4. Move regulator to position where rear (white) slider is visible through opening. 5. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 6. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 7. Install watershield and door trim panel. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 8. Repeat the lubrication process only on doors that have a regulator squeak or groan issue. REPAIR PROCEDURE - LX: 1. Remove door trim panel and watershield to access regulator rails and sliders. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Removal > Removal. 2. Lower regulator to a position where forward (white) slider is visible through opening. 3. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 4. Move regulator to position where rear (white) slider is visible through opening. 5. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 6. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 7. Install watershield and door trim panel. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 8. Repeat the lubrication process only on doors that have a regulator squeak or groan issue. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > 23-028-08 > Sep > 08 > Body - Noise When Operating Front/Rear Door Windows > Page 8893 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > Page 8894 Rear Door Window Regulator: By Symptom Technical Service Bulletin # 23-028-08 Date: 080919 Body - Noise When Operating Front/Rear Door Windows NUMBER: 23-028-08 GROUP: Body DATE: September 19, 2008 SUBJECT: Squeak or Groan Sound When Raising or Lowering Door Glass OVERVIEW: This bulletin involves lubricating the window regulator rails. MODELS: 2006 - 2007 (CS) Pacifica 2007 - 2008 (LX) 300/Magnum/Charger 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber NOTE: This bulletin applies to all 2006 - 2007 CS, 2007 - 2008 LX vehicles built before November 14th, 2007 (MDH 1114XX) and PM/MK vehicles built before May 13th 2008 (MDH 0513XX). SYMPTOM/CONDITION: Squeak or squealing sound from window regulator area when raising or lowering front or rear door glass. Groaning sound when cycling front or rear door glass to full up position. DIAGNOSIS: If the customer describes the Symptom/Condition, verify the sound is from the regulator and is not being caused by glass run seals or belt seals. If the condition is present, perform the Repair Procedure on the door. PARTS REQUIRED: REPAIR PROCEDURE - PM/MK: 1. Remove door trim bolster. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > PANEL, Door Trim > Removal > REMOVAL. 2. Remove the door speaker cover and speaker. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 08 - Electrical > 8A - Audio > Speaker > Removal > Removal. 3. Lower regulator to a position where forward (white) slider is visible through opening. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > Page 8895 4. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers (Fig 1). 5. Move regulator to position where rear (white) slider is visible through opening. 6. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers (Fig 2). 7. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 8. Install the door speaker and cover. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 08 - Electrical > 8A - Audio > Speaker > Installation > Installation. 9. Install door trim bolster. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 10. Repeat the lubrication process only on doors that have a regulator squeak or groan sound issue. REPAIR PROCEDURE - CS: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > Page 8896 1. Remove door trim panel and watershield to access regulator rails and sliders. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Removal > Removal. 2. Lower regulator to a position where forward (white) slider is visible through opening. 3. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 4. Move regulator to position where rear (white) slider is visible through opening. 5. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 6. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 7. Install watershield and door trim panel. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 8. Repeat the lubrication process only on doors that have a regulator squeak or groan issue. REPAIR PROCEDURE - LX: 1. Remove door trim panel and watershield to access regulator rails and sliders. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Removal > Removal. 2. Lower regulator to a position where forward (white) slider is visible through opening. 3. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 4. Move regulator to position where rear (white) slider is visible through opening. 5. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 6. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 7. Install watershield and door trim panel. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 8. Repeat the lubrication process only on doors that have a regulator squeak or groan issue. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > Page 8897 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 23-028-08 Date: 080919 Body - Noise When Operating Front/Rear Door Windows NUMBER: 23-028-08 GROUP: Body DATE: September 19, 2008 SUBJECT: Squeak or Groan Sound When Raising or Lowering Door Glass OVERVIEW: This bulletin involves lubricating the window regulator rails. MODELS: 2006 - 2007 (CS) Pacifica 2007 - 2008 (LX) 300/Magnum/Charger 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber NOTE: This bulletin applies to all 2006 - 2007 CS, 2007 - 2008 LX vehicles built before November 14th, 2007 (MDH 1114XX) and PM/MK vehicles built before May 13th 2008 (MDH 0513XX). SYMPTOM/CONDITION: Squeak or squealing sound from window regulator area when raising or lowering front or rear door glass. Groaning sound when cycling front or rear door glass to full up position. DIAGNOSIS: If the customer describes the Symptom/Condition, verify the sound is from the regulator and is not being caused by glass run seals or belt seals. If the condition is present, perform the Repair Procedure on the door. PARTS REQUIRED: REPAIR PROCEDURE - PM/MK: 1. Remove door trim bolster. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > PANEL, Door Trim > Removal > REMOVAL. 2. Remove the door speaker cover and speaker. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 08 - Electrical > 8A - Audio > Speaker > Removal > Removal. 3. Lower regulator to a position where forward (white) slider is visible through opening. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > Page 8898 4. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers (Fig 1). 5. Move regulator to position where rear (white) slider is visible through opening. 6. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers (Fig 2). 7. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 8. Install the door speaker and cover. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 08 - Electrical > 8A - Audio > Speaker > Installation > Installation. 9. Install door trim bolster. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 10. Repeat the lubrication process only on doors that have a regulator squeak or groan sound issue. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > Page 8899 REPAIR PROCEDURE - CS: 1. Remove door trim panel and watershield to access regulator rails and sliders. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Removal > Removal. 2. Lower regulator to a position where forward (white) slider is visible through opening. 3. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 4. Move regulator to position where rear (white) slider is visible through opening. 5. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 6. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 7. Install watershield and door trim panel. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 8. Repeat the lubrication process only on doors that have a regulator squeak or groan issue. REPAIR PROCEDURE - LX: 1. Remove door trim panel and watershield to access regulator rails and sliders. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Removal > Removal. 2. Lower regulator to a position where forward (white) slider is visible through opening. 3. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 4. Move regulator to position where rear (white) slider is visible through opening. 5. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 6. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 7. Install watershield and door trim panel. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 8. Repeat the lubrication process only on doors that have a regulator squeak or groan issue. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > Page 8900 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Removal Rear Door Window Regulator: Service and Repair Removal REMOVAL 1. Remove door module. 2. Remove door glass (5). 3. Remove fasteners, wire connectors and remove window regulator (1) from door panel. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Removal > Page 8903 Rear Door Window Regulator: Service and Repair Installation INSTALLATION 1. Fasten window regulator to door panel. 2. Connect wire connectors. 3. Install glass ensuring proper seat. 4. Install door module. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Technical Service Bulletins > Customer Interest for Fuel Door: > 14-003-07 > May > 07 > Body - Fuel Filler Door Under Flush Fuel Door: Customer Interest Body - Fuel Filler Door Under Flush NUMBER: 14-003-07 GROUP: Fuel System DATE: May 31, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-006-06, DATED AUGUST 16, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF MODELS, REPAIR PROCEDURE STEPS AND PARTS. SUBJECT: Under Flush Fuel Filler Door Splash Shield OVERVIEW: This bulletin involves installing a Fuel Filler Neck Spacer. MODELS: 2007 (PM) Caliber 2007 (MK-49) Compass **2007 (MK74) Patriot** NOTE: This bulletin applies to PM and MK-49 models built before June 22, 2006 (MDH 0622XX) **and MK74 models built prior to April 3, 2007 (MDH 0403xx)**. SYMPTOM/CONDITION: The condition may present itself as a under-flush fuel filler door or loose fuel filler neck which may be more noticeable when the vehicle is being fueled up. This condition can also be described as a loose fuel filler neck housing. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open the fuel door. 2. Pull the fuel filler housing back into place. It may be necessary to remove the splash shield to secure housing. All clips must be engaged. 3. **Refer to proper step based on vehicle being serviced: a. PM - Caliber or MK49 - Compass, go to > next step. b. MK74 - Patriot, go to > Step # 5** Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Technical Service Bulletins > Customer Interest for Fuel Door: > 14-003-07 > May > 07 > Body - Fuel Filler Door Under Flush > Page 8912 4. PM/MK49: Install the fuel filler neck spacer over the lower screw (Fig 1). NOTE: Be sure to orient the spacer correctly before installing. 5. **MK74: Install the fuel filler neck spacer over the lower screw on fuel door mount. Push spacer all the way in until it clicks** (Fig 2) POLICY: Reimbursable within the provisions of the warranty. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Technical Service Bulletins > Customer Interest for Fuel Door: > 14-003-07 > May > 07 > Body - Fuel Filler Door Under Flush > Page 8913 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Door: > 14-003-07 > May > 07 > Body - Fuel Filler Door Under Flush Fuel Door: All Technical Service Bulletins Body - Fuel Filler Door Under Flush NUMBER: 14-003-07 GROUP: Fuel System DATE: May 31, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-006-06, DATED AUGUST 16, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF MODELS, REPAIR PROCEDURE STEPS AND PARTS. SUBJECT: Under Flush Fuel Filler Door Splash Shield OVERVIEW: This bulletin involves installing a Fuel Filler Neck Spacer. MODELS: 2007 (PM) Caliber 2007 (MK-49) Compass **2007 (MK74) Patriot** NOTE: This bulletin applies to PM and MK-49 models built before June 22, 2006 (MDH 0622XX) **and MK74 models built prior to April 3, 2007 (MDH 0403xx)**. SYMPTOM/CONDITION: The condition may present itself as a under-flush fuel filler door or loose fuel filler neck which may be more noticeable when the vehicle is being fueled up. This condition can also be described as a loose fuel filler neck housing. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open the fuel door. 2. Pull the fuel filler housing back into place. It may be necessary to remove the splash shield to secure housing. All clips must be engaged. 3. **Refer to proper step based on vehicle being serviced: a. PM - Caliber or MK49 - Compass, go to > next step. b. MK74 - Patriot, go to > Step # 5** Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Door: > 14-003-07 > May > 07 > Body - Fuel Filler Door Under Flush > Page 8919 4. PM/MK49: Install the fuel filler neck spacer over the lower screw (Fig 1). NOTE: Be sure to orient the spacer correctly before installing. 5. **MK74: Install the fuel filler neck spacer over the lower screw on fuel door mount. Push spacer all the way in until it clicks** (Fig 2) POLICY: Reimbursable within the provisions of the warranty. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Door: > 14-003-07 > May > 07 > Body - Fuel Filler Door Under Flush > Page 8920 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair > Removal Fuel Door: Service and Repair Removal REMOVAL 1. Remove fuel filler door fasteners (4). 2. Remove fuel filler door. 3. Remove fuel filler housing screws. 4. Remove fuel filler housing. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair > Removal > Page 8923 Fuel Door: Service and Repair Installation INSTALLATION 1. Install fuel filler housing (2). 2. Install fuel housing screws. 3. Align fuel door (1) with fuel door holes. 4. Fasten fuel door (1) to fender (3) with fasteners. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Service and Repair > Removal Hood Hinge: Service and Repair Removal REMOVAL 1. With the help of an assistant, have the assistant hold the opposite side of hood that is being worked on. 2. Remove fasteners (2) from hinge (1). 3. Remove hood from hinge (1). 4. Repeat step if necessary. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Service and Repair > Removal > Page 8929 Hood Hinge: Service and Repair Installation INSTALLATION 1. Align hood hinge with fastener holes. 2. Install fasteners (2) in to hinge holes. 3. Tighten nuts (3) to 20 Nm (15 ft.lbs.). 4. Install hood to hinge. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Insulator / Pad > Component Information > Service and Repair > Removal Hood Insulator / Pad: Service and Repair Removal REMOVAL 1. Remove two push pins (1) fastening hood insulation (2) to hood (3). 2. Remove insulation from hood by pulling insulation outward from hood tabs. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Insulator / Pad > Component Information > Service and Repair > Removal > Page 8934 Hood Insulator / Pad: Service and Repair Installation INSTALLATION 1. Insert hood insulation (2) into hood tabs. 2. Insert push two pins (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Removal Hood Latch: Service and Repair Removal REMOVAL 1. Press down latch release (3) and remove cable (2) from grommet. 2. Remove cable from latch (3). 3. Remove fasteners. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Removal > Page 8939 Hood Latch: Service and Repair Installation INSTALLATION 1. Install cable (2) into latch (3) and route end of cable (1). Pull cable into latch (3) ensuring proper seat. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Removal Hood Latch Release Cable: Service and Repair Removal REMOVAL 1. Remove the wheel mounting nuts, then the front drivers side tire. 2. Remove front drivers side splash shield. Refer to Front Fender Liner. NOTE: See cable route. 3. Press down latch release (3) and remove cable (2) from grommet (1). 4. Remove cable (2) from latch (3). 5. Follow cable and remove cable from push pin grommets. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Removal > Page 8944 6. Remove fasteners (2) from hood release located inside vehicle. 7. Remove cable from hood release (3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Removal > Page 8945 Hood Latch Release Cable: Service and Repair Installation INSTALLATION 1. Install fasteners (2). 2. Install cable into hood release lever (3), and route cable (4) through grommet. 3. Remove splash shield. 4. Route cable along underneath splash shield and route toward radiator support. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Removal > Page 8946 5. Insert cable (2) into latch (3) and route front of cable (1) into access hole. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair Liftgate Window Glass: Service and Repair Liftgate Removal 1. Open liftgate. 2. Disconnect washer hose. 3. Disconnect liftgate harness (1). 4. Disconnect cable from handle. 5. With the help from an assistant, support liftgate and disconnect Prop rods. 6. Remove fasteners (2) attaching liftgate (1) to liftgate hinge (3). Installation Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair > Page 8951 1. With the help of an assistant, place liftgate (1) onto liftgate hinges (3). 2. Torque nuts (2) to 15 Nm (11 ft. lbs.). 3. Install prop. rods. 4. Install liftgate harness (1). 5. Install washer hose. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge > Component Information > Service and Repair > Removal Trunk / Liftgate Hinge: Service and Repair Removal REMOVAL 1. Release liftgate latch and open liftgate. 2. Disconnect liftgate harness and washer hose.. 3. Support liftgate with a suitable lifting device in the full open position on the side of the vehicle being serviced. 4. Remove the two screws that secure the liftgate hinge (1) to the liftgate. 5. Remove liftgate (1) from hinge (3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge > Component Information > Service and Repair > Removal > Page 8956 6. Carefully, move down headliner and remove two nuts and one fastener. Remove hinge from vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge > Component Information > Service and Repair > Removal > Page 8957 Trunk / Liftgate Hinge: Service and Repair Installation INSTALLATION 1. With the help of an assistant, align liftgate (1) with liftgate hinge (3). 2. Carefully, pry down headliner and install fastener, washers and nuts. 3. Tighten nuts 20 Nm (15 ft. lbs). 4. Install gas props. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge > Component Information > Service and Repair > Removal > Page 8958 5. Connect liftgate harness (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Interior Trim Panel > Component Information > Service and Repair > Liftgate Upper Molding Trunk / Liftgate Interior Trim Panel: Service and Repair Liftgate Upper Molding Removal REMOVAL 1. Using trim stick C-4755 or equivalent, pry up on upper trim(1) ensuring trim tabs disengage. 2. Remove from vehicle. Installation INSTALLATION 1. Align molding tabs (2) with holes in liftgate. 2. Hand tap trim (1) onto liftgate holes at clip locations. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Interior Trim Panel > Component Information > Service and Repair > Liftgate Upper Molding > Page 8963 Trunk / Liftgate Interior Trim Panel: Service and Repair Liftgate Upper Side Molding Removal REMOVAL 1. Using trim stick C4755 or equivalent, pry up at each clip location. 2. Remove upper side trim. Installation INSTALLATION 1. Locate and align metal clips to holes in liftgate inner. 2. Start at top clip (2) and work downward to bottom clips (3). 3. Tap on panel at each clip location until side trim (1) is properly seated. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Removal Trunk / Liftgate Latch: Service and Repair Removal REMOVAL 1. Remove three fasteners (1). 2. Disconnect wire connectors. 3. Disconnect cable from outer handle hole. 4. Disconnect cable from latch. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Removal > Page 8968 Trunk / Liftgate Latch: Service and Repair Installation INSTALLATION 1. Connect wire connectors. 2. Install latch assembly into liftgate pocket. 3. Install three fasteners (1). 4. Tighten fasteners to 8 Nm (6 ft. lbs.). 5. Install cable fastener to liftgate inner while working the cable upward. 6. Guide cable upward through opening and tuck into the outer handle hole. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Service and Repair > Removal Trunk / Liftgate Shock / Support: Service and Repair Removal REMOVAL 1. Open the liftgate and support. 2. Using a small flat bladed tool, or equivalent, release the retaining clips while pulling the ball socket away from the ball stud. NOTE: Lift the clips only enough to release the ball studs. 3. Remove the support cylinder. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Service and Repair > Removal > Page 8973 Trunk / Liftgate Shock / Support: Service and Repair Installation INSTALLATION 1. Make sure the retaining clips are seated into the ball socket (2) fully. 2. Install the support cylinder over the ball studs with the thin end connected to the liftgate and the retaining clips snapping into place. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Striker > Component Information > Service and Repair > Removal Trunk / Liftgate Striker: Service and Repair Removal REMOVAL 1. Open the liftgate. 2. Remove the liftgate sill scuff plate. Refer to Trim Panel. NOTE: Place a reference mark along the outer edge of the striker to ensure it is reinstalled to its original position. 3. Mark the position of the striker (1) on the liftgate opening lower panel to aid installation. 4. Remove the two screws (4) that secure the striker to the lower panel and remove the striker. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Striker > Component Information > Service and Repair > Removal > Page 8978 Trunk / Liftgate Striker: Service and Repair Installation INSTALLATION 1. Position the liftgate striker (1) onto the liftgate opening lower panel and align the striker to the previously marked location. 2. Install the two bolts (4) that secure the striker to the lower panel. Tighten the bolts to 23 Nm (17 ft. lbs.). 3. Verify liftgate alignment and latch operation. The liftgate should fit flush and have even gaps to adjacent body panels. Gap specifications are as follows: - 7 mm (0.280 in.) to the fascia. - 6 mm (0.240 in.) to the roof header. - 4 mm (0.160 in.) to the body side. 4. Install the liftgate sill scuff plate. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair > Removal Cowl Moulding / Trim: Service and Repair Removal REMOVAL 1. Remove the wiper arms (2). 2. Remove the hood seal (4). 3. Remove the screws (3) and remove the panel (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair > Removal > Page 8984 Cowl Moulding / Trim: Service and Repair Installation INSTALLATION 1. Position the end seals (1) into place. 2. Install the panel (2) and install the screws (3). 3. Install the hood seal (4). 4. Install the wiper arms (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > License Plate Bracket > Component Information > Technical Service Bulletins > Customer Interest for License Plate Bracket: > 23-027-07 > Jul > 07 > Body - Rear License Plate Bracket Rattling License Plate Bracket: Customer Interest Body - Rear License Plate Bracket Rattling NUMBER: 23-027-07 GROUP: Body DATE: July 11, 2007 SUBJECT: License Plate Rattle OVERVIEW: This bulletin involves checking the proper position of the isolation foam tape on the liftgate and if an aftermarket plate frame is installed, isolating the frame to prevent rattle sounds. MODELS: 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber SYMPTOM/CONDITION: Vehicle operator may experience a rattle sound from the liftgate caused by the license plate or aftermarket Dealer Installed plate frame or bracket. DIAGNOSIS: Perform a liftgate "slam test to verify the rattle is originating from the license plate or plate frame/bracket. If it is determined that the sound is being caused by the plate or plate frame, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. With chalk or tape, mark the 2 lower corners of the license plate. 2. Remove the license plate and plate frame, (if equipped). 3. Inspect to determine if foam blocks were installed on the liftgate at a location that would match the lower corners of the License Plate. 4. Are the Foam Blocks Located at the lower outer corner locations: a. Yes - Continue with Isolating the Aftermarket Frame (if equipped). If a plate frame is not installed, further diagnosis will be required to determine the rattle source. b. No - Continue with the repair. 5. Clean the liftgate in the area of the LOWER corners of the license plate with alcohol wipe or equivalent. 6. Cut 2 squares of Closed Cell Low Density Foam Tape p/n 05019058AA into .625 in (15 mm) x .625 in (15 mm) blocks. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > License Plate Bracket > Component Information > Technical Service Bulletins > Customer Interest for License Plate Bracket: > 23-027-07 > Jul > 07 > Body - Rear License Plate Bracket Rattling > Page 8993 7. Remove adhesive backing and install the blocks to the liftgate, just inside the area of the lower corners of the license plate (Fig. 1). 8. If a license plate frame is installed, foam tape should be applied to the backside of the frame to prevent rattling against the liftgate. NOTE: Use an appropriate amount of foam to isolate the frame. 9. Install plate and frame, (if equipped) on liftgate and perform a liftgate "slam test to assure the plate and or frame does not rattle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > License Plate Bracket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for License Plate Bracket: > 23-027-07 > Jul > 07 > Body Rear License Plate Bracket Rattling License Plate Bracket: All Technical Service Bulletins Body - Rear License Plate Bracket Rattling NUMBER: 23-027-07 GROUP: Body DATE: July 11, 2007 SUBJECT: License Plate Rattle OVERVIEW: This bulletin involves checking the proper position of the isolation foam tape on the liftgate and if an aftermarket plate frame is installed, isolating the frame to prevent rattle sounds. MODELS: 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber SYMPTOM/CONDITION: Vehicle operator may experience a rattle sound from the liftgate caused by the license plate or aftermarket Dealer Installed plate frame or bracket. DIAGNOSIS: Perform a liftgate "slam test to verify the rattle is originating from the license plate or plate frame/bracket. If it is determined that the sound is being caused by the plate or plate frame, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. With chalk or tape, mark the 2 lower corners of the license plate. 2. Remove the license plate and plate frame, (if equipped). 3. Inspect to determine if foam blocks were installed on the liftgate at a location that would match the lower corners of the License Plate. 4. Are the Foam Blocks Located at the lower outer corner locations: a. Yes - Continue with Isolating the Aftermarket Frame (if equipped). If a plate frame is not installed, further diagnosis will be required to determine the rattle source. b. No - Continue with the repair. 5. Clean the liftgate in the area of the LOWER corners of the license plate with alcohol wipe or equivalent. 6. Cut 2 squares of Closed Cell Low Density Foam Tape p/n 05019058AA into .625 in (15 mm) x .625 in (15 mm) blocks. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > License Plate Bracket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for License Plate Bracket: > 23-027-07 > Jul > 07 > Body Rear License Plate Bracket Rattling > Page 8999 7. Remove adhesive backing and install the blocks to the liftgate, just inside the area of the lower corners of the license plate (Fig. 1). 8. If a license plate frame is installed, foam tape should be applied to the backside of the frame to prevent rattling against the liftgate. NOTE: Use an appropriate amount of foam to isolate the frame. 9. Install plate and frame, (if equipped) on liftgate and perform a liftgate "slam test to assure the plate and or frame does not rattle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > License Plate Frame > Component Information > Technical Service Bulletins > Customer Interest for License Plate Frame: > 23-027-07 > Jul > 07 > Body - Rear License Plate Bracket Rattling License Plate Frame: Customer Interest Body - Rear License Plate Bracket Rattling NUMBER: 23-027-07 GROUP: Body DATE: July 11, 2007 SUBJECT: License Plate Rattle OVERVIEW: This bulletin involves checking the proper position of the isolation foam tape on the liftgate and if an aftermarket plate frame is installed, isolating the frame to prevent rattle sounds. MODELS: 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber SYMPTOM/CONDITION: Vehicle operator may experience a rattle sound from the liftgate caused by the license plate or aftermarket Dealer Installed plate frame or bracket. DIAGNOSIS: Perform a liftgate "slam test to verify the rattle is originating from the license plate or plate frame/bracket. If it is determined that the sound is being caused by the plate or plate frame, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. With chalk or tape, mark the 2 lower corners of the license plate. 2. Remove the license plate and plate frame, (if equipped). 3. Inspect to determine if foam blocks were installed on the liftgate at a location that would match the lower corners of the License Plate. 4. Are the Foam Blocks Located at the lower outer corner locations: a. Yes - Continue with Isolating the Aftermarket Frame (if equipped). If a plate frame is not installed, further diagnosis will be required to determine the rattle source. b. No - Continue with the repair. 5. Clean the liftgate in the area of the LOWER corners of the license plate with alcohol wipe or equivalent. 6. Cut 2 squares of Closed Cell Low Density Foam Tape p/n 05019058AA into .625 in (15 mm) x .625 in (15 mm) blocks. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > License Plate Frame > Component Information > Technical Service Bulletins > Customer Interest for License Plate Frame: > 23-027-07 > Jul > 07 > Body - Rear License Plate Bracket Rattling > Page 9008 7. Remove adhesive backing and install the blocks to the liftgate, just inside the area of the lower corners of the license plate (Fig. 1). 8. If a license plate frame is installed, foam tape should be applied to the backside of the frame to prevent rattling against the liftgate. NOTE: Use an appropriate amount of foam to isolate the frame. 9. Install plate and frame, (if equipped) on liftgate and perform a liftgate "slam test to assure the plate and or frame does not rattle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > License Plate Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for License Plate Frame: > 23-027-07 > Jul > 07 > Body - Rear License Plate Bracket Rattling License Plate Frame: All Technical Service Bulletins Body - Rear License Plate Bracket Rattling NUMBER: 23-027-07 GROUP: Body DATE: July 11, 2007 SUBJECT: License Plate Rattle OVERVIEW: This bulletin involves checking the proper position of the isolation foam tape on the liftgate and if an aftermarket plate frame is installed, isolating the frame to prevent rattle sounds. MODELS: 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber SYMPTOM/CONDITION: Vehicle operator may experience a rattle sound from the liftgate caused by the license plate or aftermarket Dealer Installed plate frame or bracket. DIAGNOSIS: Perform a liftgate "slam test to verify the rattle is originating from the license plate or plate frame/bracket. If it is determined that the sound is being caused by the plate or plate frame, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. With chalk or tape, mark the 2 lower corners of the license plate. 2. Remove the license plate and plate frame, (if equipped). 3. Inspect to determine if foam blocks were installed on the liftgate at a location that would match the lower corners of the License Plate. 4. Are the Foam Blocks Located at the lower outer corner locations: a. Yes - Continue with Isolating the Aftermarket Frame (if equipped). If a plate frame is not installed, further diagnosis will be required to determine the rattle source. b. No - Continue with the repair. 5. Clean the liftgate in the area of the LOWER corners of the license plate with alcohol wipe or equivalent. 6. Cut 2 squares of Closed Cell Low Density Foam Tape p/n 05019058AA into .625 in (15 mm) x .625 in (15 mm) blocks. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > License Plate Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for License Plate Frame: > 23-027-07 > Jul > 07 > Body - Rear License Plate Bracket Rattling > Page 9014 7. Remove adhesive backing and install the blocks to the liftgate, just inside the area of the lower corners of the license plate (Fig. 1). 8. If a license plate frame is installed, foam tape should be applied to the backside of the frame to prevent rattling against the liftgate. NOTE: Use an appropriate amount of foam to isolate the frame. 9. Install plate and frame, (if equipped) on liftgate and perform a liftgate "slam test to assure the plate and or frame does not rattle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Underbody Cover > Component Information > Service and Repair > Removal Underbody Cover: Service and Repair Removal REMOVAL 1. Remove fasteners from belly pan. 2. Carefully, remove belly pan from vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Underbody Cover > Component Information > Service and Repair > Removal > Page 9019 Underbody Cover: Service and Repair Installation INSTALLATION 1. Position belly pan on to vehicle 2. Install fasteners. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair > Removal Front Fender Liner: Service and Repair Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the front wheels. 3. Remove push pins (2) and (3). 4. Remove screws (4) and (5) 5. Remove splash shield (6) from wheelhouse. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair > Removal > Page 9026 Front Fender Liner: Service and Repair Installation INSTALLATION 1. Raise and support vehicle. 2. Remove front wheels. 3. Raise splash shield (5) up to wheel house and align with holes in quarter panel (6). 4. Install push pins (2)and (3). 5. Install screws (6) and (4). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Fender > Rear Fender > Rear Fender Liner > System Information > Service and Repair > Removal Rear Fender Liner: Service and Repair Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the left and right rear wheel. 3. Remove push pins (2) and (3). 4. Remove fasteners (4). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Fender > Rear Fender > Rear Fender Liner > System Information > Service and Repair > Removal > Page 9032 Rear Fender Liner: Service and Repair Installation INSTALLATION NOTE: Left hand side has 2 additional push pins as it has additional material to cover the fuel filler tube. 1. Place splash shield (1) up to wheel house (5) and align splash shield holes with fender. 2. Install fasteners (4). 3. Install push pins (2) and (3). 4. Install the rear wheels. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Service and Repair > Front Crossmember Fore/Aft Front Cross-Member: Service and Repair Front Crossmember Fore/Aft Removal REMOVAL 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the four wheel well screws. 3. If equipped, remove the three front screws (4), the three rear screws (2) and one push pin fastener from the center of the belly pan. 4. Remove the crossmember bolts (1, 2 and 3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Service and Repair > Front Crossmember Fore/Aft > Page 9039 5. Remove the engine roll mount (3) through bolt (2) and remove the fore/aft crossmember (4). Installation INSTALLATION 1. Install the fore/aft crossmember and install the engine anti-roll mount (3) through bolt (2). 2. Install the bolts (1, 2 and 3), and tighten using the following sequence: a. Tighten the bolt (1) to 78 Nm (58 ft. lbs.). b. Tighten the bolt (2) to 78 Nm (58 ft. lbs.). c. Tighten the bolt (3) to 129 Nm (95 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Service and Repair > Front Crossmember Fore/Aft > Page 9040 3. Tighten the bolt (2) to 65 Nm (48 ft. lbs.). 4. If equipped, install the belly pan. 5. Install the three front screws (4), the three rear screws (2) and on push pin fastener into the center of the belly pan. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Service and Repair > Front Crossmember Fore/Aft > Page 9041 Front Cross-Member: Service and Repair Front Suspension Crossmember Removal REMOVAL 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the four wheel well screws. 3. If equipped, remove the three front screws (4), the three rear screws (2) and one push pin fastener from the center of the belly pan. 4. Remove the rear roll mount (4) through bolt (2). 5. Remove the three bolts (3) attaching the rear roll mount (5) to the crossmember and remove the mount. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Service and Repair > Front Crossmember Fore/Aft > Page 9042 6. Remove the for/aft crossmember (4). 7. Remove the front wheels (1). 8. Remove the lower ball joint (6) pinch bolts (4) and nuts (5). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Service and Repair > Front Crossmember Fore/Aft > Page 9043 9. Remove the bolt attaching the pressure line routing bracket to the steering gear. 10. Remove the bolt attaching the return line to the crossmember. 11. Remove the sway bar bushing bolts (1) and support the sway bar (2) up in the vehicle. 12. Remove the steering gear mounting bolts (1) and support the steering gear (2) up in the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Service and Repair > Front Crossmember Fore/Aft > Page 9044 13. Mark the crossmember (3) to body location (1) using a grease pencil (2) or equivalent. 14. Support the crossmember with a suitable lifting device. 15. Remove the crossmember bolts (1 and 2) and lower the crossmember from the vehicle. 16. Remove the lower control arm (3) front pivot bolts (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Service and Repair > Front Crossmember Fore/Aft > Page 9045 17. Remove the lower control arm rear pivot bolts (3) and separate the lower control arms from the crossmember (1). Installation INSTALLATION 1. Install the lower control arms and install the rear pivot bolts (3). 2. Install the front pivot bolts (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Service and Repair > Front Crossmember Fore/Aft > Page 9046 3. Support the crossmember on a suitable lifting device. 4. Raise the crossmember into position onto the vehicle. 5. Install the bolts (1 and 2) and align the engine cradle to the marks made during removal. 6. Tighten the bolts to 190 Nm (140 ft. lbs.). 7. Position the steering gear back into place and install the bolts (1). 8. Tighten the bolts to 61 Nm (45 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Service and Repair > Front Crossmember Fore/Aft > Page 9047 9. Position the stabilizer bar (2) back into place and install the bushing bolts (1). 10. Tighten the bolts to 61 Nm (45 ft. lbs.). 11. Position the power steering lines back into place and install the support bracket (2) bolts (1). 12. Tighten the bolts to 8 Nm (70 ft. lbs.). 13. Connect the lower ball joint stud (6) to the knuckle (3). 14. Install a NEW ball joint stud pinch bolt (4) and nut (5). Tighten the nut to 82 Nm (60 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Service and Repair > Front Crossmember Fore/Aft > Page 9048 15. Install the fore/aft crossmember (4). 16. Install the front wheels (1). 17. With the full weight of the vehicle on the suspension tighten the front control arm bushing bolts to 123 Nm (91 ft. lbs.) 18. Perform wheel alignment as necessary. 19. Install the rear roll mount (4) and install the three bolts (3) attaching it to the crossmember. 20. Tighten the bolts (3) to 153 Nm (112 ft. lbs.). 21. Install the through bolt (2) and tighten to 65 Nm (48 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Service and Repair > Front Crossmember Fore/Aft > Page 9049 22. If equipped, install the belly pan. 23. Install the three front screws (4), the three rear screws (2) and push pin fasteners into the center of the belly pan. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Removal Rear Cross-Member: Service and Repair Removal REMOVAL 1. Remove the park brake shoes. 2. Park brake cable from lever. 3. Remove the hair pin clip and separate the brake cable (2) from the backing plate (3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Removal > Page 9054 4. Remove the bolt (2) and separate the brake line (1) from the trailing arm (3). 5. Remove the bolt (1), the clip (2) and separate the brake line (3) from the trailing arm. 6. Separate the wheel speed sensors and position aside as necessary to remove the crossmember. 7. If equipped, remove the rear drive module. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Removal > Page 9055 8. Remove the cotter pins (2), the nuts (3) and the washers (4). 9. Remove both half shafts. 10. Remove the lower strut bolts. 11. Remove the trailing link bushing bolts. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Removal > Page 9056 12. Support the rear cradle with a suitable lifting device. 13. Remove the rear cradle bolts and lower the cradle assembly from vehicle. 14. Remove the lower stabilizer link nuts (2). 15. Remove the lower link bolts (5 and 6) at the cradle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Removal > Page 9057 16. Remove the upper link bolts (2) at the cradle. 17. Remove the toe link cam bolts (1) at the cradle. 18. Remove the suspension knuckle assemblies. 19. Remove the stabilizer bushing bolts (1) and separate the stabilizer bar from the cradle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Removal > Page 9058 Rear Cross-Member: Service and Repair Installation INSTALLATION 1. Install the stabilizer bar and install the bushings and bolts (1). 2. Tighten the bolts to 61 Nm (45 ft. lbs.). 3. Position the suspension knuckle assemblies back into position onto the crossmember. 4. Install the toe link cam bolts (1) at the cradle. 5. Tighten the bolts to 35 Nm (26 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Removal > Page 9059 6. Install the upper link bolts (2) at the cradle. 7. Tighten the bolts to 90 Nm (70 ft. lbs.). 8. Install the lower link bolts (5 and 6) at the cradle. 9. Tighten the bolts to 90 Nm (70 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Removal > Page 9060 10. Install the stabilizer link nuts (2). 11. Tighten the nuts to 58 Nm (43 ft. lbs.). 12. Support the rear cradle assembly (1) with a suitable lifting device and position back into the vehicle. 13. Install the cradle bolts (2 and 3): a. Tighten the front bolts (2) first to 110 Nm (81 ft. lbs.). b. Tighten the rear bolts (3) next to 110 Nm (81 ft. lbs.). 14. Install the trailing link (1) bushing bolts (2 and 3): a. Tighten the inboard bolts (3) first to 110 Nm (81 ft. lbs.). b. Tighten the outboard bolts (2) next to 110 Nm (81 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Removal > Page 9061 15. Install the lower strut bolts (1). 16. Tighten the bolts to 99 Nm 73 ft. lbs.). 17. If equipped, install the rear half shafts. 18. Install the nuts (3) and washers (4). 19. Tighten the nuts to 244 Nm (180 ft. lbs.). 20. Install new cotter pins (2). 21. Install the rear drive module (1). 22. Install the wheel speed sensor back. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Removal > Page 9062 23. Position the brake lines (3) back into place, connect the clips (2) and install the bolts (1). 24. Tighten the bolts to 15 Nm (11 ft. lbs.). 25. Position the brake lines (1) back into place, and install the bolts (2). 26. Tighten the bolts to 23 Nm (17 ft. lbs.). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Removal > Page 9063 27. Install the brake cable (2) onto the backing plate (3) and install the hair pin clip (1). 28. Connect the brake cable to the park brake lever. 29. Install the park brake shoes. 30. Check and adjust wheel alignment as necessary. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > Customer Interest for Arm Rest: > 23-029-06 > Jul > 06 > Interior - Console Arm Rest Slides Too Easily Arm Rest: Customer Interest Interior - Console Arm Rest Slides Too Easily NUMBER: 23-029-06 GROUP: Body DATE: July 26, 2005 SUBJECT: Console Armrest Slides Too Easy Or Will Not Stay In Place OVERVIEW: This bulletin involves replacing the armrest console. MODELS: 2007 (PM) Caliber 2007 (MK-49) Compass NOTE: This bulletin applies to vehicles built before July 3, 2006 (MDH 0703XX). SYMPTOM/CONDITION: The center console arm rest moves too easily or will not stay in place. This may also happen while the vehicle is stopping or accelerating. DIAGNOSIS: If the center console arm rest moves too easily or will not stay in place, as described in the Symptom/Condition listed above perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Open door. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > Customer Interest for Arm Rest: > 23-029-06 > Jul > 06 > Interior - Console Arm Rest Slides Too Easily > Page 9073 2. Using a trim stick (C-4755) remove the armrest console. Wedge the trim stick between the latch and the armrest console assembly (Fig. 1). 3. Transfer the flip pocket from the old armrest console to the new armrest console. 4. Install the new armrest console. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Arm Rest: > 23-029-06 > Jul > 06 > Interior - Console Arm Rest Slides Too Easily Arm Rest: All Technical Service Bulletins Interior - Console Arm Rest Slides Too Easily NUMBER: 23-029-06 GROUP: Body DATE: July 26, 2005 SUBJECT: Console Armrest Slides Too Easy Or Will Not Stay In Place OVERVIEW: This bulletin involves replacing the armrest console. MODELS: 2007 (PM) Caliber 2007 (MK-49) Compass NOTE: This bulletin applies to vehicles built before July 3, 2006 (MDH 0703XX). SYMPTOM/CONDITION: The center console arm rest moves too easily or will not stay in place. This may also happen while the vehicle is stopping or accelerating. DIAGNOSIS: If the center console arm rest moves too easily or will not stay in place, as described in the Symptom/Condition listed above perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Open door. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Arm Rest: > 23-029-06 > Jul > 06 > Interior - Console Arm Rest Slides Too Easily > Page 9079 2. Using a trim stick (C-4755) remove the armrest console. Wedge the trim stick between the latch and the armrest console assembly (Fig. 1). 3. Transfer the flip pocket from the old armrest console to the new armrest console. 4. Install the new armrest console. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Floor Carpet Carpet: Service and Repair Floor Carpet Removal REMOVAL 1. Remove front seats. 2. Remove rear seats cushion. 3. Remove rear seat back. 4. Remove cargo load floor. 5. Remove center console. 6. Remove center console shifter housing. 7. Remove lower B-Pillar trim. Refer to Trim Panel. 8. Remove door sill plate. Refer to Trim Panel. 9. Remove side cowl trim panel. Refer to Trim Panel. 10. Remove liftgate scuff plate. Refer to Trim Panel. 11. Remove rear quarter trim. Refer to Trim Panel. 12. Remove carpet from vehicle. Installation INSTALLATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Floor Carpet > Page 9084 1. Install carpet into vehicle ensuring carpet (1) is aligned with tabs (2). 2. Install rear quarter panel trim. 3. Install liftgate scuff plate. 4. Install cargo load floor. 5. Install side cowl trim panel. 6. Install B-pillar lower trim. 7. Install door sill scuff plate. 8. Install center console. 9. Install center console shifter housing. 10. Install rear seat cushion. 11. Install rear seat back. 12. Install front seats. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Floor Carpet > Page 9085 Carpet: Service and Repair Cover Assembly Cargo Floor Removal REMOVAL 1. Pull upward on cargo load floor (1) disengaging tabs. 2. Pull outward at rear of cargo load floor removing cargo load floor disengaging cargo load floor from rear quarter panel pockets. 3. Remove from vehicle. Installation INSTALLATION 1. Load cargo load floor (1) into vehicle, ensuring cargo load floor pivots fit into pockets onto the rear quarter trim panel. 2. Once rear cargo load floor pivots are properly seated into pockets, snap down the front cargo load floor tabs ensuring cargo load floor is seated. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Customer Interest for Console: > 23-029-06 > Jul > 06 > Interior - Console Arm Rest Slides Too Easily Console: Customer Interest Interior - Console Arm Rest Slides Too Easily NUMBER: 23-029-06 GROUP: Body DATE: July 26, 2005 SUBJECT: Console Armrest Slides Too Easy Or Will Not Stay In Place OVERVIEW: This bulletin involves replacing the armrest console. MODELS: 2007 (PM) Caliber 2007 (MK-49) Compass NOTE: This bulletin applies to vehicles built before July 3, 2006 (MDH 0703XX). SYMPTOM/CONDITION: The center console arm rest moves too easily or will not stay in place. This may also happen while the vehicle is stopping or accelerating. DIAGNOSIS: If the center console arm rest moves too easily or will not stay in place, as described in the Symptom/Condition listed above perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Open door. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Customer Interest for Console: > 23-029-06 > Jul > 06 > Interior - Console Arm Rest Slides Too Easily > Page 9094 2. Using a trim stick (C-4755) remove the armrest console. Wedge the trim stick between the latch and the armrest console assembly (Fig. 1). 3. Transfer the flip pocket from the old armrest console to the new armrest console. 4. Install the new armrest console. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 23-029-06 > Jul > 06 > Interior - Console Arm Rest Slides Too Easily Console: All Technical Service Bulletins Interior - Console Arm Rest Slides Too Easily NUMBER: 23-029-06 GROUP: Body DATE: July 26, 2005 SUBJECT: Console Armrest Slides Too Easy Or Will Not Stay In Place OVERVIEW: This bulletin involves replacing the armrest console. MODELS: 2007 (PM) Caliber 2007 (MK-49) Compass NOTE: This bulletin applies to vehicles built before July 3, 2006 (MDH 0703XX). SYMPTOM/CONDITION: The center console arm rest moves too easily or will not stay in place. This may also happen while the vehicle is stopping or accelerating. DIAGNOSIS: If the center console arm rest moves too easily or will not stay in place, as described in the Symptom/Condition listed above perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Open door. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 23-029-06 > Jul > 06 > Interior - Console Arm Rest Slides Too Easily > Page 9100 2. Using a trim stick (C-4755) remove the armrest console. Wedge the trim stick between the latch and the armrest console assembly (Fig. 1). 3. Transfer the flip pocket from the old armrest console to the new armrest console. 4. Install the new armrest console. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Center Console Console: Service and Repair Center Console Removal REMOVAL 1. Pull back on parking brake (5) to the upright position. 2. Remove front screws (1) fastening center console to front floor bracket (6). 3. Open console door and remove two screws (1) fastening console to rear floor bracket (3). 4. Disconnect center console wire connector (2) to instrument panel connector. 5. Remove from vehicle. Installation INSTALLATION 1. Pull parking brake (5) into upright position. 2. Insert center console over parking brake. 3. Connect console wiring connector (2) to instrument panel connector (4). 4. Insert and fasten two front screws (1) into front floor bracket (6). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Center Console > Page 9103 5. Insert and fasten two rear screws (1) into rear floor bracket (3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Center Console > Page 9104 Console: Service and Repair Center Console Shifter Housing Removal REMOVAL 1. Remove shift knob and shift bezel. 2. Remove two screws (1). 3. Pull on side of housing (1) and unsnap housing tabs. 4. Disconnect console housing wire connector (2) and instrument panel connector (3). 5. Remove from vehicle. Installation INSTALLATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Center Console > Page 9105 1. Connect center console housing wire connector (2) with instrument panel connector (3). 2. Place console housing (1) over shifter lever ensuring console tabs seat properly. 3. Install screws (1). 4. Replace shift bezel and knob. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Glove Box-Cooler Door Glove Compartment: Service and Repair Glove Box-Cooler Door Removal REMOVAL 1. Open glove box cooler door (1). 2. Unsnap glove box cooler door from glove box door opening tabs (1). 3. Remove glove box cooler door from vehicle. Installation INSTALLATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Glove Box-Cooler Door > Page 9110 1. Align cooler door with cooler door opening tabs (1). 2. Snap cooler door (1) on to door opening tabs. 3. Shut cooler door. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Glove Box-Cooler Door > Page 9111 Glove Compartment: Service and Repair Instrument Panel Glove Box - Removal REMOVAL 1. Open glove box latch. 2. Unsnap glove box damper from glove box bin. 3. Flex glove box open position stops (1) inboard and rotate past stops. 4. Unsnap glove box door from base panel lower hinge pins (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Glove Box-Cooler Door > Page 9112 Glove Compartment: Service and Repair Instrument Panel Glove Box - Installation INSTALLATION 1. Align glove box door with glove box opening. 2. Snap glove box door hinge pins (2) to lower base panel hinges. 3. Flex glove box inboard and rotate inward past stops (1). 4. Close glove box. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Customer Interest for Headliner: > 23-043-06 > Oct > 06 > Body - Water Leaking From Headliner After Rain/Carwash Headliner: Customer Interest Body - Water Leaking From Headliner After Rain/Carwash NUMBER: 23-043-06 GROUP: Body DATE: October 7, 2006 SUBJECT: Water Leak From Headliner OVERVIEW: This bulletin involves diagnosing the leak path at the sunroof and repairing the sunroof drain hose(s). MODELS: 2007 (MK-49) Compass 2007 (PM) Caliber NOTE: This bulletin applies to vehicles equipped with a sunroof (sales code GWG) built prior to October 6, 2006 (MDH 0908XX). SYMPTOM/CONDITION: Water leaking from headliner after a heavy rain or car wash. DIAGNOSIS: If the vehicle exhibits the Symptom/Condition perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open sunroof. 2. Pour water directly into the left front corner drain hole in Sunroof Front Crossmember NOTE: Water should drain fully and not overflow over Sunroof Housing channel inboard edge. Drain hose system should drain approximately 20 oz. of water when poured into the Sunroof Track over 20 seconds. Begin pouring slowly, if no water drains, STOP, do not pour additional water. 3. Does approximately 20 oz. of water drain out in 20 seconds? a. Yes - Proceed to Step # 7 b. No - Proceed to Step # 4. 4. Gain access to left front drain tube. Refer to 23 - Body/Sunroof/Drain Tube - Removal available in TechCONNECT. 5. Check left front drain tube for cuts, kinks or pinch points. NOTE: Be sure to check for kinks at the pass through grommet at the dash. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Customer Interest for Headliner: > 23-043-06 > Oct > 06 > Body - Water Leaking From Headliner After Rain/Carwash > Page 9121 6. Is drain hose cut? a. Yes - Replace left front drain tube. b. No - remove kink/pinch in drain tube. 7. Pour water directly into the right front corner drain hole in Sunroof Front Crossmember 8. Does approximately 20 oz. of water drain out in 20 seconds? a. Yes - Proceed to Step # 14 b. No - Proceed to Step # 9. 9. Gain access to right front drain tube. Refer to 23 - Body/Sunroof/Drain Tube - Removal available in TechCONNECT. 10. Check right front drain tube to see if it is wrapped around the rear washer fluid supply hose. 11. Is drain tube wrapped around the washer fluid supply hose? a. Yes - Unwrap hoses and retest. b. No - Proceed to Step # 12 12. Check right front drain tube for cuts, kinks or pinch points. NOTE: Be sure to check for kinks at the pass through grommet at the dash. 13. Is drain tube cut? a. Yes - Replace right front drain tube. b. remove kink/pinch in drain tube. 14. Pour water directly into the left rear drain hole in Sunroof Front Crossmember 15. Does approximately 20 oz. of water drain out in 20 seconds? a. Yes - Proceed to Step # 19 b. No - Proceed to Step # 16 16. Gain access to left rear drain tube. Refer to 23 - Body/Sunroof/Drain Tube - Removal available in TechCONNECT. 17. Check left rear drain tube for cuts, kinks or pinch points. 18. Is drain tube cut? a. Yes - Replace left rear drain tube. b. remove kink/pinch in drain tube. 19. Pour water directly into the right rear drain hole in Sunroof Front Crossmember 20. Does approximately 20 oz. of water drain out in 20 seconds? a. Yes - Further Diagnosis required b. No - Proceed to Step # 21 21. Gain access to right rear drain tube. Refer to 23 - Body/Sunroof/Drain Tube - Removal available in TechCONNECT. 22. Check right rear drain tube for cuts, kinks or pinch points. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Customer Interest for Headliner: > 23-043-06 > Oct > 06 > Body - Water Leaking From Headliner After Rain/Carwash > Page 9122 23. Is drain tube cut? a. Yes - Replace right rear drain tube. b. remove kink/pinch in drain tube. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headliner: > 23-043-06 > Oct > 06 > Body - Water Leaking From Headliner After Rain/Carwash Headliner: All Technical Service Bulletins Body - Water Leaking From Headliner After Rain/Carwash NUMBER: 23-043-06 GROUP: Body DATE: October 7, 2006 SUBJECT: Water Leak From Headliner OVERVIEW: This bulletin involves diagnosing the leak path at the sunroof and repairing the sunroof drain hose(s). MODELS: 2007 (MK-49) Compass 2007 (PM) Caliber NOTE: This bulletin applies to vehicles equipped with a sunroof (sales code GWG) built prior to October 6, 2006 (MDH 0908XX). SYMPTOM/CONDITION: Water leaking from headliner after a heavy rain or car wash. DIAGNOSIS: If the vehicle exhibits the Symptom/Condition perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open sunroof. 2. Pour water directly into the left front corner drain hole in Sunroof Front Crossmember NOTE: Water should drain fully and not overflow over Sunroof Housing channel inboard edge. Drain hose system should drain approximately 20 oz. of water when poured into the Sunroof Track over 20 seconds. Begin pouring slowly, if no water drains, STOP, do not pour additional water. 3. Does approximately 20 oz. of water drain out in 20 seconds? a. Yes - Proceed to Step # 7 b. No - Proceed to Step # 4. 4. Gain access to left front drain tube. Refer to 23 - Body/Sunroof/Drain Tube - Removal available in TechCONNECT. 5. Check left front drain tube for cuts, kinks or pinch points. NOTE: Be sure to check for kinks at the pass through grommet at the dash. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headliner: > 23-043-06 > Oct > 06 > Body - Water Leaking From Headliner After Rain/Carwash > Page 9128 6. Is drain hose cut? a. Yes - Replace left front drain tube. b. No - remove kink/pinch in drain tube. 7. Pour water directly into the right front corner drain hole in Sunroof Front Crossmember 8. Does approximately 20 oz. of water drain out in 20 seconds? a. Yes - Proceed to Step # 14 b. No - Proceed to Step # 9. 9. Gain access to right front drain tube. Refer to 23 - Body/Sunroof/Drain Tube - Removal available in TechCONNECT. 10. Check right front drain tube to see if it is wrapped around the rear washer fluid supply hose. 11. Is drain tube wrapped around the washer fluid supply hose? a. Yes - Unwrap hoses and retest. b. No - Proceed to Step # 12 12. Check right front drain tube for cuts, kinks or pinch points. NOTE: Be sure to check for kinks at the pass through grommet at the dash. 13. Is drain tube cut? a. Yes - Replace right front drain tube. b. remove kink/pinch in drain tube. 14. Pour water directly into the left rear drain hole in Sunroof Front Crossmember 15. Does approximately 20 oz. of water drain out in 20 seconds? a. Yes - Proceed to Step # 19 b. No - Proceed to Step # 16 16. Gain access to left rear drain tube. Refer to 23 - Body/Sunroof/Drain Tube - Removal available in TechCONNECT. 17. Check left rear drain tube for cuts, kinks or pinch points. 18. Is drain tube cut? a. Yes - Replace left rear drain tube. b. remove kink/pinch in drain tube. 19. Pour water directly into the right rear drain hole in Sunroof Front Crossmember 20. Does approximately 20 oz. of water drain out in 20 seconds? a. Yes - Further Diagnosis required b. No - Proceed to Step # 21 21. Gain access to right rear drain tube. Refer to 23 - Body/Sunroof/Drain Tube - Removal available in TechCONNECT. 22. Check right rear drain tube for cuts, kinks or pinch points. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headliner: > 23-043-06 > Oct > 06 > Body - Water Leaking From Headliner After Rain/Carwash > Page 9129 23. Is drain tube cut? a. Yes - Replace right rear drain tube. b. remove kink/pinch in drain tube. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headliner - Removal Headliner: Service and Repair Headliner - Removal REMOVAL 1. Remove front windshield. 2. Remove A-pillar trim. Refer to Trim Panel. 3. Disconnect A-pillar trim wire connector (2). 4. Remove sunvisors. 5. Remove sun visor screws and retainers. 6. Disconnect front washer hose (1). 7. Remove universal homelink module and connector. 8. Remove and disconnect dome lamp. 9. Remove front and rear grab handles (3). 10. Remove seat belt turning loops. 11. Remove B-pillar upper trim. Refer to Trim Panel. 12. Remove B-pillar lower trim. Refer to Trim Panel. 13. Remove fastener attaching cargo loop to rear quarter trim. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headliner - Removal > Page 9132 14. Remove rear seat striker bezel. 15. Remove C-pillar trim. Refer to Trim Panel. 16. Remove rear quarter trim. Refer to Trim Panel. 17. Remove cargo load floor. Refer to Trim Panel. 18. Remove liftgate scuff plate. Refer to Trim Panel. 19. Remove rear cargo dome light and disconnect connector. 20. Remove rear headliner push pins. 21. Disconnect rear washer hose connector 22. Lower headliner. 23. With the help of an assistant, remove headliner through front windshield opening. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headliner - Removal > Page 9133 Headliner: Service and Repair Headliner - Installation INSTALLATION 1. Before headliner installation, install courtesy lamp, cargo lamp, and Universal transmitter module to headliner. 2. With the help of an assistant, Install headliner through windshield opening. 3. Connect rear cargo lamp connector. 4. Install headliner push pins located at rear of headliner. 5. Connect front dome lamp connector. 6. If equipped, connect home link module connector. 7. Connect front rear view mirror hardware. 8. Install rear view mirror. 9. Install grab handles (3). 10. Connect rear washer hose. 11. Install sunvisor retainers. 12. Install sun visors. 13. Connect A-pillar wire connector. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headliner - Removal > Page 9134 14. Install A-pillar trim. 15. Install scuff plate. 16. Install B-pillar lower trim. 17. Install B-pillar upper trim. 18. Install cargo load floor. 19. Install rear quarter trim. 20. Install C-pillar trim. 21. Install rear seat striker bezel. 22. Install seat belt turning loops. 23. Install rear cargo scuff plate. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information > Service and Repair > Scuff Plate-Door Sill Scuff Plate: Service and Repair Scuff Plate-Door Sill Removal REMOVAL 1. Using trim stick C-4755, pry up scuff plate. 2. Remove scuff plate from vehicle. Installation INSTALLATION 1. Place scuff plate (1) onto door sill (2). 2. Align scuff plate tabs with door scuff holes. 3. Hand press scuff plate ensuring tabs are properly seated. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information > Service and Repair > Scuff Plate-Door Sill > Page 9139 Scuff Plate: Service and Repair Scuff Plate-Liftgate Sill Removal REMOVAL 1. Using trim stick C-4755 or equivalent, pry up on each scuff plate clip location hole (2). 2. Remove scuff plate (1). Installation INSTALLATION 1. Locate trim clips and align metal clips to liftgate inner. 2. Tap on panel at each trim clip location (2) until properly seated. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair > Sun Visor Sun Visor: Service and Repair Sun Visor Removal REMOVAL 1. Disengage the sun visor (2) from the sun visor support. 2. Remove the two screws that secure the sun visor to the roof panel and remove the sun visor from the headliner (1). 3. If equipped, disconnect the illuminated vanity mirror wire harness connector. Installation INSTALLATION 1. If equipped, connect the illuminated vanity mirror wire harness connector. 2. Position the sun visor (2) on the headliner (1) and install the two screws that secure the sun visor to the roof panel. 3. Engage the sun visor and sun visor support. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair > Sun Visor > Page 9144 Sun Visor: Service and Repair Visor Support Removal REMOVAL 1. Disengage the sun visor (1) from the sun visor support (2). 2. Remove the screw that secures the support to the roof panel and remove the support from the headliner (3). Installation INSTALLATION 1. Position the sun visor support (2) on the headliner (3) and install the screw that secures the support to the roof panel. 2. Engage the sun visor (1) and sun visor support. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim Trim Panel: Service and Repair Cowl Trim Removal REMOVAL NOTE: Left hand shown, right side similar. 1. Remove door sill scuff plate. 2. Remove nut (3) securing trim (1) to dash. 3. Using trim stick C-4755, pry up on cowl trim and remove from vehicle. Installation INSTALLATION 1. Place tab cowl trim (1) over stud on dash and wrap door flange. 2. Align hole for park brake release handle and clip on trim to hole (2) in cowl side. 3. Install nut (3) and fasten until cowl trim is seated. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 9149 Trim Panel: Service and Repair Front Door Trim Panel Removal REMOVAL 1. Remove pull-cup screw (1). 2. Remove window crank (1) from spindle if equipped. 3. Using trim stick C-4755, start at the lower corner and pull in the direction of the arrows. Bolster should unsnap. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 9150 4. Remove sock seal (1) and (3) that wraps around switch bezel and wire harness. Disconnect wire connectors (2). 5. Remove switch bezel from bolster. 6. Remove bolster by unsnapping plastic tethers (1) from bolster back side of surface. Installation INSTALLATION 1. Connect bolster to door module tethers (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 9151 2. Connect wire connectors (2) and close sock seal (1). 3. Replace window crank (1) to spindle. 4. Replace pull cup screw. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 9152 Trim Panel: Service and Repair Liftgate Trim Panel W/Out Speaker REMOVAL 1. Remove upper liftgate molding. 2. Remove liftgate upper side molding. 3. Remove liftgate screws (2) from liftgate nuts (1). 4. Using special tool C-4755, pry up liftgate trim tabs (4) from liftgate. 5. Remove lower liftgate trim (3) from vehicle. W/ Speaker REMOVAL 1. Remove trim panel fasteners (2). 2. Using trimstick C-4755, pry up on trim panel and remove trim panel from liftgate. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 9153 3. Remove six speaker fasteners. 4. Disconnect speaker wire from harness. W/Out Speaker INSTALLATION 1. Align lower liftgate trim tabs (4) with liftgate holes. 2. Hand tap liftgate panel ensuring liftgate tabs are properly seated. 3. Install liftgate screws (2) into liftgate nuts (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 9154 4. Install upper side molding. 5. Install upper liftgate molding. W/ Speaker INSTALLATION 1. Connect speaker connector to wire harness. 2. Fasten speaker to liftgate. 3. Align trim panel to liftgate holes and install trim panel fasteners. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 9155 Trim Panel: Service and Repair Pillar Trim A-Pillar Trim Panel-Removal REMOVAL 1. Using special tool C-4755, remove plug (1) from A-pillar.. 2. Remove screw. 3. Remove A-pillar trim. A-Pillar Trim Panel-Installation INSTALLATION 1. Insert A-Pillar trim bottom first ensuring trim has seated into clips. 2. Install screw. NOTE: It is very important to insert small tab of plug into small trim opening. 3. Insert plug bottom first (2) into trim opening. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 9156 4. Hinge A-pillar plug upward ensuring proper seat.. Removal REMOVAL 1. Using special tool C-4755, pry off B-pillar lower trim. 2. Remove from vehicle. Installation INSTALLATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 9157 1. Insert lower tabs on B-pillar lower trim (1) onto sill panel. 2. Hand tap on clip locations ensuring clips are properly seated. Removal REMOVAL 1. Remove lower B-pillar trim from B-pillar (5). 2. Remove plug. 3. Remove screw (3). 4. Remove trim (1) by pulling tab (2) on top outward. Installation INSTALLATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 9158 1. Install B-pillar (1) trim to B-pillar (5) by inserting B-pillar trim tab (2) into B-pillar slot. 2. Push B-pillar trim into position ensuring bottom clip (4) has seated. 3. Add screw (3) and reinstall plug. Removal REMOVAL 1. Remove lower quarter. 2. Remove lower seat anchors from seat belt opening (1). 3. Remove upper quarter by pulling on rear portion of upper quarter disengaging clips from metal holes in body (4). 4. Remove front lower portion (3) by pulling clip loose. 5. Slide quarter panel (2) downward and remove from vehicle. Installation INSTALLATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 9159 1. Pass seat belt anchors through trim openings (1). 2. Install quarter trim (2) by sliding hook at top and locating 4-way locator into the body side sheet metal holes (4). 3. Complete installation by aligning metal clips and snaping until properly seated. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 9160 Trim Panel: Service and Repair Removal REMOVAL NOTE: Left hand shown, right side similar. 1. Remove door sill scuff plate. 2. Remove nut (3) securing trim (1) to dash. 3. Using trim stick C-4755, pry up on cowl trim and remove from vehicle. Installation INSTALLATION 1. Place tab cowl trim (1) over stud on dash and wrap door flange. 2. Align hole for park brake release handle and clip on trim to hole (2) in cowl side. 3. Install nut (3) and fasten until cowl trim is seated. Removal REMOVAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 9161 1. Remove pull-cup screw (1). 2. Remove window crank (1) from spindle if equipped. 3. Using trim stick C-4755, start at the lower corner and pull in the direction of the arrows. Bolster should unsnap. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 9162 4. Remove sock seal (1) and (3) that wraps around switch bezel and wire harness. Disconnect wire connectors (2). 5. Remove switch bezel from bolster. 6. Remove bolster by unsnapping plastic tethers (1) from bolster back side of surface. Installation INSTALLATION 1. Connect bolster to door module tethers (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 9163 2. Connect wire connectors (2) and close sock seal (1). 3. Replace window crank (1) to spindle. 4. Replace pull cup screw. W/Out Speaker REMOVAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 9164 1. Remove upper liftgate molding. 2. Remove liftgate upper side molding. 3. Remove liftgate screws (2) from liftgate nuts (1). 4. Using special tool C-4755, pry up liftgate trim tabs (4) from liftgate. 5. Remove lower liftgate trim (3) from vehicle. W/ Speaker REMOVAL 1. Remove trim panel fasteners (2). 2. Using trimstick C-4755, pry up on trim panel and remove trim panel from liftgate. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 9165 3. Remove six speaker fasteners. 4. Disconnect speaker wire from harness. W/Out Speaker INSTALLATION 1. Align lower liftgate trim tabs (4) with liftgate holes. 2. Hand tap liftgate panel ensuring liftgate tabs are properly seated. 3. Install liftgate screws (2) into liftgate nuts (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 9166 4. Install upper side molding. 5. Install upper liftgate molding. W/ Speaker INSTALLATION 1. Connect speaker connector to wire harness. 2. Fasten speaker to liftgate. 3. Align trim panel to liftgate holes and install trim panel fasteners. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 9167 A-Pillar Trim Panel-Removal REMOVAL 1. Using special tool C-4755, remove plug (1) from A-pillar.. 2. Remove screw. 3. Remove A-pillar trim. A-Pillar Trim Panel-Installation INSTALLATION 1. Insert A-Pillar trim bottom first ensuring trim has seated into clips. 2. Install screw. NOTE: It is very important to insert small tab of plug into small trim opening. 3. Insert plug bottom first (2) into trim opening. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 9168 4. Hinge A-pillar plug upward ensuring proper seat.. Removal REMOVAL 1. Using special tool C-4755, pry off B-pillar lower trim. 2. Remove from vehicle. Installation INSTALLATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 9169 1. Insert lower tabs on B-pillar lower trim (1) onto sill panel. 2. Hand tap on clip locations ensuring clips are properly seated. Removal REMOVAL 1. Remove lower B-pillar trim from B-pillar (5). 2. Remove plug. 3. Remove screw (3). 4. Remove trim (1) by pulling tab (2) on top outward. Installation INSTALLATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 9170 1. Install B-pillar (1) trim to B-pillar (5) by inserting B-pillar trim tab (2) into B-pillar slot. 2. Push B-pillar trim into position ensuring bottom clip (4) has seated. 3. Add screw (3) and reinstall plug. Removal REMOVAL 1. Remove lower quarter. 2. Remove lower seat anchors from seat belt opening (1). 3. Remove upper quarter by pulling on rear portion of upper quarter disengaging clips from metal holes in body (4). 4. Remove front lower portion (3) by pulling clip loose. 5. Slide quarter panel (2) downward and remove from vehicle. Installation INSTALLATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 9171 1. Pass seat belt anchors through trim openings (1). 2. Install quarter trim (2) by sliding hook at top and locating 4-way locator into the body side sheet metal holes (4). 3. Complete installation by aligning metal clips and snaping until properly seated. Quarter Trim Panel - Removal REMOVAL 1. Remove the rear quarter trim cargo loop (2) retaining screw. NOTE: If removing the right side lower quarter trim panel, remove the sub woofer (if equipped). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 9172 2. Remove cargo floor. 3. Remove liftgate scuff plate. 4. Remove B-pillar lower trim. 5. Remove the door sill scuff plate. 6. Remove the upper C-pillar trim. 7. Remove the rear quarter panel trim (4). Quarter Trim Panel - Installation INSTALLATION 1. Position the rear quarter panel trim (4) over the retaining slots and firmly snap into place. 2. Install the door sill scuff plate. 3. Install the B-pillar lower trim. 4. Install the upper C-pillar trim. 5. Install the liftgate scuff plate. 6. Install the cargo floor. NOTE: If equipped with a sub woofer, install at this time. 7. Install the cargo loop (2) and screw. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 9173 Rear Door Trim Panel REMOVAL 1. Remove screw (1) from pull cup. 2. If equipped, remove window crank (4) and washer (5) from bolster (3). 3. Using trim stick C-4755, unsnap bolster from door panel. 4. If equipped, disconnect wire connector from window switch. INSTALLATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 9174 1. Connect wire harness (7) to window switch connector (4). 2. Align bolster (3) with door and hand tap bolster to door ensuring fit. 3. Insert screw (1) into pull cup and tighten. Automatic REMOVAL 1. Pull up on shifter knob (1) and remove. 2. Using trim stick C-4755 or equivalent, pry up on bezel (2) and remove from shifter pod (3). Manual REMOVAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 9175 1. Pull up on shifter knob (3) and remove. 2. Using trim stick C-4755 or equivalent, pry up on bezel (1) and remove from shifter pod (4). Automatic INSTALLATION 1. Insert bezel (2) locator to shifter pod (3). 2. Apply hand pressure until clips are seated. 3. Snap shifter knob (1) onto shifter shaft. 4. Pull up on knob (1) to verify seated correctly. Manual INSTALLATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 9176 1. Locate bezel (1) over shifter lever (5) and into shifter pod (4). 2. Insert bezel locator to shifter pod (4). 3. Apply hand pressure to bezel (1) until clips are seated. 4. Slide boot (2) over shift lever (5) to bezel (1). 5. Apply hand pressure to snap bottom of boot (2) into bezel (1). 6. Snap shifter knob (3) onto shifter lever (5). 7. Pull up on know to verify seated correctly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Component ID: 161 Component : MODULE-SENTRY KEY REMOTE ENTRY/WCM Connector: Name : MODULE-SENTRY KEY REMOTE ENTRY/WCM Color : BLACK # of pins : 8 Pin Description Circuit 1 IGNITION SWITCH SENSE G20 20VT/BR 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4 GROUND Z937 20BK/YL 5 FUSED B(+) (I.O.D.) A411 20RD/LG 6 CAN B BUS (+) D55 20WT/OR 7 CAN B BUS (-) D54 20WT/PK 8-Component Location - 28 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 9182 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 9183 Keyless Entry Module: Diagrams Component ID: 161 Component : MODULE-SENTRY KEY REMOTE ENTRY/WCM Connector: Name : MODULE-SENTRY KEY REMOTE ENTRY/WCM Color : BLACK # of pins : 8 Pin Description Circuit 1 IGNITION SWITCH SENSE G20 20VT/BR 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4 GROUND Z937 20BK/YL 5 FUSED B(+) (I.O.D.) A411 20RD/LG 6 CAN B BUS (+) D55 20WT/OR 7 CAN B BUS (-) D54 20WT/PK 8-Component Location - 28 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 9184 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Description and Operation > Description Keyless Entry Module: Description and Operation Description DESCRIPTION When a PCM and the SKREEM are replaced at the same time, perform the following steps in order: 1. Program the new PCM. 2. Program the new SKREEM. 3. Replace all ignition keys and program them to the new SKREEM. The Sentry Key REmote Entry Module (SKREEM) is sometimes referred to as the Wireless Control Module (WCM). The SKREEM/WCM is the primary component of the Sentry Key Immobilizer System (SKIS). It is also the receiver for the Remote Keyless Entry (RKE) system and the Tire Pressure Monitor (TPM) system. The SKREEM/WCM is located on the steering column, around the ignition lock cylinder housing and is concealed beneath the steering column shrouds. The molded black plastic housing for the SKREEM/WCM has an integral molded plastic halo-like antenna ring (3) that extends from one side. When the SKREEM/WCM is properly installed, the antenna ring is oriented around the ignition lock cylinder housing. A single connector (4) is located next to the antenna ring on the SKREEM/WCM housing (3). A molded plastic mounting tab (2) on the SKREEM/WCM housing secures the unit to the steering column. The SKREEM/WCM is connected to the vehicle electrical system through the instrument panel wire harness. The SKREEM/WCM cannot be adjusted or repaired. If faulty or damaged, the entire SKREEM unit must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Description and Operation > Description > Page 9187 Keyless Entry Module: Description and Operation Operation OPERATION The Sentry Key REmote Entry Module (SKREEM), sometimes referred to as the Wireless Control Module (WCM), contains a Radio Frequency (RF) transceiver and a microprocessor. The SKREEM/WCM transmits RF signals to, and receives RF signals from the Sentry Key transponder through a tuned antenna enclosed within the molded plastic antenna ring integral to the SKREEM/WCM housing. If this antenna ring is not mounted properly around the ignition lock cylinder housing, communication problems between the SKREEM/WCM and the transponder may arise. These communication problems will result in Sentry Key transponder-related faults. The SKREEM also serves as the Remote Keyless Entry (RKE) RF receiver and, if the vehicle is so equipped, the receiver for the Tire Pressure Monitoring (TPM) system. The SKREEM/WCM communicates over the Controller Area Network (CAN) data bus with the Electromechanical Instrument Cluster (EMIC) (sometimes referred to as the Cab Compartment Node (CCN), the Powertrain Control Module (PCM), and/or the diagnostic scan tool. The SKREEM/WCM retains in memory the ID numbers of any Sentry Key transponder that is programmed into it. A maximum of eight Sentry Key transponders can be programmed into the SKREEM/WCM. For added system security, each SKREEM/WCM is programmed with a unique Secret Key code. This code is stored in memory, sent over the CAN data bus to the PCM, and is encoded to the transponder of every Sentry Key that is programmed into the SKREEM/WCM. Therefore, the Secret Key code is a common element that is found in every component of the Sentry Key Immobilizer System (SKIS). Another security code, called a PIN, is used to gain access to the SKREEM/WCM Secured Access Mode. The Secured Access Mode is required during service to perform the SKIS initialization and Sentry Key transponder programming procedures. The SKREEM/WCM also stores the Vehicle Identification Number (VIN) in its memory, which it learns through a CAN data bus message from the PCM during SKIS initialization. NOTE: After a SKREEM/WCM is replaced, the ignition/transponder keys need to be programmed to the new SKREEM/WCM. Follow the directions on the diagnostic scan tool. The transponder key for the SKREES/SKIM and the RKE will both be programmed during this operation. There is no need to program the fob of the key for RKE functionality once the transponder key is programmed to the new SKREEM/WCM. In the event that a SKREEM/WCM replacement is required, the Secret Key code can be transferred to the new SKREEM/WCM from the PCM using the diagnostic scan tool and the SKIS initialization procedure. Proper completion of the SKIS initialization will allow the existing Sentry Keys to be programmed into the new SKREEM/WCM so that new keys will not be required. In the event that the original Secret Key code cannot be recovered, SKREEM/WCM replacement will also require new Sentry Keys. The diagnostic scan tool will alert the technician during the SKIS initialization procedure if new Sentry Keys are required. When the ignition switch is turned to the On position, the SKREEM/WCM transmits an RF signal to the transponder in the ignition key. The SKREEM/WCM then waits for an RF signal response from the transponder. If the response received identifies the key as valid, the SKREEM/WCM sends a valid key message to the PCM over the CAN data bus. If the response received identifies the key as invalid or if no response is received from the key transponder, the SKREEM/WCM sends an invalid key message to the PCM. The PCM will enable or disable engine operation based upon the status of the SKREEM/WCM messages. It is important to note that the default condition in the PCM is an invalid key; therefore, if no message is received from the SKREEM/WCM by the PCM, the engine will be disabled and the vehicle immobilized after two seconds of running. The SKREEM/WCM also sends security indicator status messages to the EMIC/CCN over the CAN data bus to tell the EMIC/CCN how to operate the security indicator. The security indicator status message from the SKREEM/WCM tells the EMIC/CCN to turn the indicator on for about three seconds each time the ignition switch is turned to the On position as a bulb test. After completion of the bulb test, the SKREEM/WCM sends security indicator status messages to the EMIC/CCN to turn the indicator off, turn the indicator on, or to flash the indicator on and off. If the security indicator flashes or stays on solid after the bulb test, it signifies a SKIS fault. If the SKREEM/WCM detects a system malfunction and/or the SKIS has become inoperative, the security indicator will stay on solid. If the SKREEM/WCM detects an invalid key or if a key transponder-related fault exists, the security indicator will flash. If the vehicle is equipped with the Customer Learn transponder programming feature, the SKREEM/WCM will also send messages to the EMIC/CCN to flash the security indicator whenever the Customer Learn programming mode is being utilized. The SKIS performs a self-test each time the ignition switch is turned to the On position, and will store fault information in the form of a Diagnostic Trouble Code (DTC) in SKREEM/WCM memory if a system malfunction is detected. The SKREEM/WCM can be diagnosed, and any stored DTC can be retrieved using a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Description and Operation > Page 9188 Keyless Entry Module: Testing and Inspection REMOTE KEYLESS ENTRY MODULE The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic information. Refer to the appropriate wiring information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair > Removal Keyless Entry Module: Service and Repair Removal REMOVAL NOTE: The steering wheel does not have to be removed to service the SKREEM/WCM. NOTE: The Steering Column Control Module (SCCM) assembly, which consists of the left/right multi-function switches and the clockspring, does not have to be removed to service the SKREEM/WCM. There is an access hole in the top of the right multi-function switch to access the mounting screw (2). 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. 2. Remove the upper and lower steering column shrouds. 3. Remove the SKREEM/WCM mounting screw (2) on the ignition lock assembly and separate the SKREEM/WCM (3) from the ignition lock assembly. 4. Disconnect the SKREEM/WCM electrical connector (4). 5. Remove SKREEM/WCM (1 and 3) from column (2). When a PCM and the SKREEM/WCM are replaced at the same time, perform the following steps in order. - Program the new PCM. - Program the new SKREEM/WCM. - Replace all ignition keys and program them to the new SKREEM/WCM. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair > Removal > Page 9191 Keyless Entry Module: Service and Repair Installation INSTALLATION When a PCM and the SKREEM/WCM are replaced at the same time, perform the following steps in order. - Program the new PCM. - Program the new SKREEM/WCM. - Replace all ignition keys and program them to the new SKREEM/WCM. 1. Position the SKREEM/WCM (3) on the ignition lock housing and install the retaining screw (2). 2. Connect the SKREEM/WCM electrical connector (4). NOTE: On vehicles equipped with the optional Sentry Key Immobilizer System (SKIS), when the SKREEM is replaced with a new unit, a diagnostic scan tool MUST be used to initialize the new SKREEM and to program at least two Sentry Key transponders before the vehicle can be operated. 3. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > System Information > Technical Service Bulletins > Customer Interest for Keyless Starting System: > 08-018-07 > Jun > 07 > Remote Start System - RKE Inop/Alarm Sounds Keyless Starting System: Customer Interest Remote Start System - RKE Inop/Alarm Sounds NUMBER: 08-018-07 GROUP: Electrical DATE: June 23, 2007 SUBJECT: Mopar Remote Start System - RKE - Intermittent Operation Or Alarm May Sound OVERVIEW: This bulletin involves the installation of a Mopar Remote Start System - Service Repair Kit. MODELS: 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) 2007 (HB/HG) Durango/Aspen 2007 (JK) Wrangler 2008 (J527) Sebring Convertible 2007 (JS) Sebring 2007-2008 (JS) Avenger 2007 (KA) Nitro 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to vehicles installed with a Mopar Remote Start Installation Kit. SYMPTOM/CONDITION: On vehicles that have had a Mopar Remote Start installation Kit installed by a dealer, the customer may experience one or more of the following conditions: A). ON ALL VEHICLES: An intermittent operation of the Remote Keyless Entry (RKE) system. At times, the RKE system may not function as designed. This may include intermittent operation of: lock/unlock mode, remote start mode, or panic mode. The vehicle may be operated manually without issue using the ignition key to open or lock the door, and to start the vehicle. B). ON RAM TRUCK AND DURANGO/ASPEN VEHICLES ONLY: The vehicle alarm may sound when the RKE system is activated by use of the key FOB. Deactivation of the vehicle alarm occurs when the vehicle engine is started using the ignition switch and key. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > System Information > Technical Service Bulletins > Customer Interest for Keyless Starting System: > 08-018-07 > Jun > 07 > Remote Start System - RKE Inop/Alarm Sounds > Page 9200 The above condition(s) may be present ONLY if one of the following specific kit part numbers for the Mopar Remote Start Installation Kit had been installed previously on the suspect vehicle. DIAGNOSIS: If the customer has experienced the above condition, and the vehicle has had a Mopar Remote Start Installation Kit installed, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Install the Remote Start Service Repair Kit. Refer to the detailed instructions included with the repair kit. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > System Information > Technical Service Bulletins > Customer Interest for Keyless Starting System: > 18-018-07 > Jun > 07 > Remote Starting System - RKE, Int. Operation/Alarm Keyless Starting System: Customer Interest Remote Starting System - RKE, Int. Operation/Alarm NUMBER: 18-018-07 GROUP: Electrical DATE: June 23, 2007 SUBJECT: Mopar Remote Start System - RKE - Intermittent Operation Or Alarm May Sound OVERVIEW: This bulletin involves the installation of a Mopar Remote Start System - Service Repair Kit. MODELS: 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) 2007 (HB/HG) Durango/Aspen 2007 (JK) Wrangler 2008 (J527) Sebring Convertible 2007 (JS) Sebring 2007-2008 (JS) Avenger 2007 (KA) Nitro 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to vehicles installed with a Mopar Remote Start Installation Kit. SYMPTOM/CONDITION: On vehicles that have had a Mopar Remote Start installation Kit installed by a dealer, the customer may experience one or more of the following conditions: A). ON ALL VEHICLES: An intermittent operation of the Remote Keyless Entry (RKE) system. At times, the RKE system may not function as designed. This may include intermittent operation of: lock/unlock mode, remote start mode, or panic mode. The vehicle may be operated manually without issue using the ignition key to open or lock the door, and to start the vehicle. B). ON RAM TRUCK AND DURANGO/ASPEN VEHICLES ONLY: The vehicle alarm may sound when the RKE system is activated by use of the key FOB. Deactivation of the vehicle alarm occurs when the vehicle engine is started using the ignition switch and key. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > System Information > Technical Service Bulletins > Customer Interest for Keyless Starting System: > 18-018-07 > Jun > 07 > Remote Starting System - RKE, Int. Operation/Alarm > Page 9205 The above condition(s) may be present ONLY if one of the following specific kit part numbers for the Mopar Remote Start Installation Kit had been installed previously on the suspect vehicle. DIAGNOSIS: If the customer has experienced the above condition, and the vehicle has had a Mopar Remote Start Installation Kit installed, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Install the Remote Start Service Repair Kit. Refer to the detailed instructions included with the repair kit. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > 08-018-07 > Jun > 07 > Remote Start System - RKE Inop/Alarm Sounds Keyless Starting System: All Technical Service Bulletins Remote Start System - RKE Inop/Alarm Sounds NUMBER: 08-018-07 GROUP: Electrical DATE: June 23, 2007 SUBJECT: Mopar Remote Start System - RKE - Intermittent Operation Or Alarm May Sound OVERVIEW: This bulletin involves the installation of a Mopar Remote Start System - Service Repair Kit. MODELS: 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) 2007 (HB/HG) Durango/Aspen 2007 (JK) Wrangler 2008 (J527) Sebring Convertible 2007 (JS) Sebring 2007-2008 (JS) Avenger 2007 (KA) Nitro 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to vehicles installed with a Mopar Remote Start Installation Kit. SYMPTOM/CONDITION: On vehicles that have had a Mopar Remote Start installation Kit installed by a dealer, the customer may experience one or more of the following conditions: A). ON ALL VEHICLES: An intermittent operation of the Remote Keyless Entry (RKE) system. At times, the RKE system may not function as designed. This may include intermittent operation of: lock/unlock mode, remote start mode, or panic mode. The vehicle may be operated manually without issue using the ignition key to open or lock the door, and to start the vehicle. B). ON RAM TRUCK AND DURANGO/ASPEN VEHICLES ONLY: The vehicle alarm may sound when the RKE system is activated by use of the key FOB. Deactivation of the vehicle alarm occurs when the vehicle engine is started using the ignition switch and key. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > 08-018-07 > Jun > 07 > Remote Start System - RKE Inop/Alarm Sounds > Page 9211 The above condition(s) may be present ONLY if one of the following specific kit part numbers for the Mopar Remote Start Installation Kit had been installed previously on the suspect vehicle. DIAGNOSIS: If the customer has experienced the above condition, and the vehicle has had a Mopar Remote Start Installation Kit installed, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Install the Remote Start Service Repair Kit. Refer to the detailed instructions included with the repair kit. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > 18-018-07 > Jun > 07 > Remote Starting System - RKE, Int. Operation/Alarm Keyless Starting System: All Technical Service Bulletins Remote Starting System - RKE, Int. Operation/Alarm NUMBER: 18-018-07 GROUP: Electrical DATE: June 23, 2007 SUBJECT: Mopar Remote Start System - RKE - Intermittent Operation Or Alarm May Sound OVERVIEW: This bulletin involves the installation of a Mopar Remote Start System - Service Repair Kit. MODELS: 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) 2007 (HB/HG) Durango/Aspen 2007 (JK) Wrangler 2008 (J527) Sebring Convertible 2007 (JS) Sebring 2007-2008 (JS) Avenger 2007 (KA) Nitro 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to vehicles installed with a Mopar Remote Start Installation Kit. SYMPTOM/CONDITION: On vehicles that have had a Mopar Remote Start installation Kit installed by a dealer, the customer may experience one or more of the following conditions: A). ON ALL VEHICLES: An intermittent operation of the Remote Keyless Entry (RKE) system. At times, the RKE system may not function as designed. This may include intermittent operation of: lock/unlock mode, remote start mode, or panic mode. The vehicle may be operated manually without issue using the ignition key to open or lock the door, and to start the vehicle. B). ON RAM TRUCK AND DURANGO/ASPEN VEHICLES ONLY: The vehicle alarm may sound when the RKE system is activated by use of the key FOB. Deactivation of the vehicle alarm occurs when the vehicle engine is started using the ignition switch and key. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > 18-018-07 > Jun > 07 > Remote Starting System - RKE, Int. Operation/Alarm > Page 9216 The above condition(s) may be present ONLY if one of the following specific kit part numbers for the Mopar Remote Start Installation Kit had been installed previously on the suspect vehicle. DIAGNOSIS: If the customer has experienced the above condition, and the vehicle has had a Mopar Remote Start Installation Kit installed, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Install the Remote Start Service Repair Kit. Refer to the detailed instructions included with the repair kit. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > Page 9217 Keyless Starting System: By Symptom Technical Service Bulletin # 18-018-07 Date: 070623 Remote Starting System - RKE, Int. Operation/Alarm NUMBER: 18-018-07 GROUP: Electrical DATE: June 23, 2007 SUBJECT: Mopar Remote Start System - RKE - Intermittent Operation Or Alarm May Sound OVERVIEW: This bulletin involves the installation of a Mopar Remote Start System - Service Repair Kit. MODELS: 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) 2007 (HB/HG) Durango/Aspen 2007 (JK) Wrangler 2008 (J527) Sebring Convertible 2007 (JS) Sebring 2007-2008 (JS) Avenger 2007 (KA) Nitro 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to vehicles installed with a Mopar Remote Start Installation Kit. SYMPTOM/CONDITION: On vehicles that have had a Mopar Remote Start installation Kit installed by a dealer, the customer may experience one or more of the following conditions: A). ON ALL VEHICLES: An intermittent operation of the Remote Keyless Entry (RKE) system. At times, the RKE system may not function as designed. This may include intermittent operation of: lock/unlock mode, remote start mode, or panic mode. The vehicle may be operated manually without issue using the ignition key to open or lock the door, and to start the vehicle. B). ON RAM TRUCK AND DURANGO/ASPEN VEHICLES ONLY: The vehicle alarm may sound when the RKE system is activated by use of the key FOB. Deactivation of the vehicle alarm occurs when the vehicle engine is started using the ignition switch and key. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > Page 9218 The above condition(s) may be present ONLY if one of the following specific kit part numbers for the Mopar Remote Start Installation Kit had been installed previously on the suspect vehicle. DIAGNOSIS: If the customer has experienced the above condition, and the vehicle has had a Mopar Remote Start Installation Kit installed, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Install the Remote Start Service Repair Kit. Refer to the detailed instructions included with the repair kit. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 08-018-07 Date: 070623 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > Page 9219 Remote Start System - RKE Inop/Alarm Sounds NUMBER: 08-018-07 GROUP: Electrical DATE: June 23, 2007 SUBJECT: Mopar Remote Start System - RKE - Intermittent Operation Or Alarm May Sound OVERVIEW: This bulletin involves the installation of a Mopar Remote Start System - Service Repair Kit. MODELS: 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) 2007 (HB/HG) Durango/Aspen 2007 (JK) Wrangler 2008 (J527) Sebring Convertible 2007 (JS) Sebring 2007-2008 (JS) Avenger 2007 (KA) Nitro 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to vehicles installed with a Mopar Remote Start Installation Kit. SYMPTOM/CONDITION: On vehicles that have had a Mopar Remote Start installation Kit installed by a dealer, the customer may experience one or more of the following conditions: A). ON ALL VEHICLES: An intermittent operation of the Remote Keyless Entry (RKE) system. At times, the RKE system may not function as designed. This may include intermittent operation of: lock/unlock mode, remote start mode, or panic mode. The vehicle may be operated manually without issue using the ignition key to open or lock the door, and to start the vehicle. B). ON RAM TRUCK AND DURANGO/ASPEN VEHICLES ONLY: The vehicle alarm may sound when the RKE system is activated by use of the key FOB. Deactivation of the vehicle alarm occurs when the vehicle engine is started using the ignition switch and key. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > Page 9220 The above condition(s) may be present ONLY if one of the following specific kit part numbers for the Mopar Remote Start Installation Kit had been installed previously on the suspect vehicle. DIAGNOSIS: If the customer has experienced the above condition, and the vehicle has had a Mopar Remote Start Installation Kit installed, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Install the Remote Start Service Repair Kit. Refer to the detailed instructions included with the repair kit. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 18-018-07 Date: 070623 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > Page 9221 Remote Starting System - RKE, Int. Operation/Alarm NUMBER: 18-018-07 GROUP: Electrical DATE: June 23, 2007 SUBJECT: Mopar Remote Start System - RKE - Intermittent Operation Or Alarm May Sound OVERVIEW: This bulletin involves the installation of a Mopar Remote Start System - Service Repair Kit. MODELS: 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) 2007 (HB/HG) Durango/Aspen 2007 (JK) Wrangler 2008 (J527) Sebring Convertible 2007 (JS) Sebring 2007-2008 (JS) Avenger 2007 (KA) Nitro 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to vehicles installed with a Mopar Remote Start Installation Kit. SYMPTOM/CONDITION: On vehicles that have had a Mopar Remote Start installation Kit installed by a dealer, the customer may experience one or more of the following conditions: A). ON ALL VEHICLES: An intermittent operation of the Remote Keyless Entry (RKE) system. At times, the RKE system may not function as designed. This may include intermittent operation of: lock/unlock mode, remote start mode, or panic mode. The vehicle may be operated manually without issue using the ignition key to open or lock the door, and to start the vehicle. B). ON RAM TRUCK AND DURANGO/ASPEN VEHICLES ONLY: The vehicle alarm may sound when the RKE system is activated by use of the key FOB. Deactivation of the vehicle alarm occurs when the vehicle engine is started using the ignition switch and key. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > Page 9222 The above condition(s) may be present ONLY if one of the following specific kit part numbers for the Mopar Remote Start Installation Kit had been installed previously on the suspect vehicle. DIAGNOSIS: If the customer has experienced the above condition, and the vehicle has had a Mopar Remote Start Installation Kit installed, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Install the Remote Start Service Repair Kit. Refer to the detailed instructions included with the repair kit. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 08-018-07 Date: 070623 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > Page 9223 Remote Start System - RKE Inop/Alarm Sounds NUMBER: 08-018-07 GROUP: Electrical DATE: June 23, 2007 SUBJECT: Mopar Remote Start System - RKE - Intermittent Operation Or Alarm May Sound OVERVIEW: This bulletin involves the installation of a Mopar Remote Start System - Service Repair Kit. MODELS: 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) 2007 (HB/HG) Durango/Aspen 2007 (JK) Wrangler 2008 (J527) Sebring Convertible 2007 (JS) Sebring 2007-2008 (JS) Avenger 2007 (KA) Nitro 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to vehicles installed with a Mopar Remote Start Installation Kit. SYMPTOM/CONDITION: On vehicles that have had a Mopar Remote Start installation Kit installed by a dealer, the customer may experience one or more of the following conditions: A). ON ALL VEHICLES: An intermittent operation of the Remote Keyless Entry (RKE) system. At times, the RKE system may not function as designed. This may include intermittent operation of: lock/unlock mode, remote start mode, or panic mode. The vehicle may be operated manually without issue using the ignition key to open or lock the door, and to start the vehicle. B). ON RAM TRUCK AND DURANGO/ASPEN VEHICLES ONLY: The vehicle alarm may sound when the RKE system is activated by use of the key FOB. Deactivation of the vehicle alarm occurs when the vehicle engine is started using the ignition switch and key. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > Page 9224 The above condition(s) may be present ONLY if one of the following specific kit part numbers for the Mopar Remote Start Installation Kit had been installed previously on the suspect vehicle. DIAGNOSIS: If the customer has experienced the above condition, and the vehicle has had a Mopar Remote Start Installation Kit installed, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Install the Remote Start Service Repair Kit. Refer to the detailed instructions included with the repair kit. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 18-018-07 Date: 070623 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > Page 9225 Remote Starting System - RKE, Int. Operation/Alarm NUMBER: 18-018-07 GROUP: Electrical DATE: June 23, 2007 SUBJECT: Mopar Remote Start System - RKE - Intermittent Operation Or Alarm May Sound OVERVIEW: This bulletin involves the installation of a Mopar Remote Start System - Service Repair Kit. MODELS: 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) 2007 (HB/HG) Durango/Aspen 2007 (JK) Wrangler 2008 (J527) Sebring Convertible 2007 (JS) Sebring 2007-2008 (JS) Avenger 2007 (KA) Nitro 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to vehicles installed with a Mopar Remote Start Installation Kit. SYMPTOM/CONDITION: On vehicles that have had a Mopar Remote Start installation Kit installed by a dealer, the customer may experience one or more of the following conditions: A). ON ALL VEHICLES: An intermittent operation of the Remote Keyless Entry (RKE) system. At times, the RKE system may not function as designed. This may include intermittent operation of: lock/unlock mode, remote start mode, or panic mode. The vehicle may be operated manually without issue using the ignition key to open or lock the door, and to start the vehicle. B). ON RAM TRUCK AND DURANGO/ASPEN VEHICLES ONLY: The vehicle alarm may sound when the RKE system is activated by use of the key FOB. Deactivation of the vehicle alarm occurs when the vehicle engine is started using the ignition switch and key. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > Page 9226 The above condition(s) may be present ONLY if one of the following specific kit part numbers for the Mopar Remote Start Installation Kit had been installed previously on the suspect vehicle. DIAGNOSIS: If the customer has experienced the above condition, and the vehicle has had a Mopar Remote Start Installation Kit installed, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Install the Remote Start Service Repair Kit. Refer to the detailed instructions included with the repair kit. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 08-018-07 Date: 070623 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > Page 9227 Remote Start System - RKE Inop/Alarm Sounds NUMBER: 08-018-07 GROUP: Electrical DATE: June 23, 2007 SUBJECT: Mopar Remote Start System - RKE - Intermittent Operation Or Alarm May Sound OVERVIEW: This bulletin involves the installation of a Mopar Remote Start System - Service Repair Kit. MODELS: 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) 2007 (HB/HG) Durango/Aspen 2007 (JK) Wrangler 2008 (J527) Sebring Convertible 2007 (JS) Sebring 2007-2008 (JS) Avenger 2007 (KA) Nitro 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (PM) Caliber NOTE: This bulletin applies to vehicles installed with a Mopar Remote Start Installation Kit. SYMPTOM/CONDITION: On vehicles that have had a Mopar Remote Start installation Kit installed by a dealer, the customer may experience one or more of the following conditions: A). ON ALL VEHICLES: An intermittent operation of the Remote Keyless Entry (RKE) system. At times, the RKE system may not function as designed. This may include intermittent operation of: lock/unlock mode, remote start mode, or panic mode. The vehicle may be operated manually without issue using the ignition key to open or lock the door, and to start the vehicle. B). ON RAM TRUCK AND DURANGO/ASPEN VEHICLES ONLY: The vehicle alarm may sound when the RKE system is activated by use of the key FOB. Deactivation of the vehicle alarm occurs when the vehicle engine is started using the ignition switch and key. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > System Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > Page 9228 The above condition(s) may be present ONLY if one of the following specific kit part numbers for the Mopar Remote Start Installation Kit had been installed previously on the suspect vehicle. DIAGNOSIS: If the customer has experienced the above condition, and the vehicle has had a Mopar Remote Start Installation Kit installed, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Install the Remote Start Service Repair Kit. Refer to the detailed instructions included with the repair kit. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service and Repair Keyless Entry Transmitter Battery: Service and Repair STANDARD PROCEDURE - RKE TRANSMITTER BATTERIES The Remote Keyless Entry (RKE) transmitter case snaps open and shut for battery access. To replace the RKE transmitter batteries: 1. Using a thin coin, gently pry at the notch in the center seam of the RKE transmitter case halves near the key ring until the two halves unsnap. 2. Lift the back half of the transmitter case off of the RKE transmitter. 3. Remove the two batteries from the RKE transmitter. 4. Replace the two batteries with new Panasonic 2016, or equivalent. Be certain that the batteries are installed with their polarity correctly oriented. 5. Align the two RKE transmitter case halves with each other, and squeeze them firmly and evenly together until they snap back into place. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Latch-Door-Driver Power Door Lock Actuator: Locations Latch-Door-Driver Component ID: 137 Component : LATCH-DOOR-DRIVER Connector: Name : LATCH-DOOR-DRIVER Color : BLACK # of pins : 4 Qualifier : (LHD BASE) Pin Description Circuit 1-2-3 LEFT FRONT DOOR AJAR SWITCH SENSE G75 20VT/DB 4 GROUND Z928 20BK/LG Component Location - 53 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Latch-Door-Driver > Page 9238 Connector: Name : LATCH-DOOR-DRIVER Color : BLACK # of pins : 4 Qualifier : (LHD EXCEPT BASE) Pin Description Circuit 1 DRIVER DOOR UNLOCK DRIVER P238 20TN/DG 2 DOOR LOCK DRIVER P33 20TN/DB 3 LEFT FRONT DOOR AJAR SWITCH SENSE G75 20VT/DB 4 GROUND Z928 20BK/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Latch-Door-Driver > Page 9239 Component Location - 53 Connector: Name : LATCH-DOOR-DRIVER Color : # of pins : 8 Qualifier : (RHD) Pin Description Circuit 1-- Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Latch-Door-Driver > Page 9240 2-3 SECONDARY UNLOCK DRIVER P237 20DG/TN 4 SECONDARY LOCK DRIVER P235 20LG/TN 5 DRIVER DOOR UNLOCK DRIVER P238 20TN/RD 6 DOOR LOCK DRIVER P33 20TN/DB 7 RIGHT FRONT DOOR AJAR SWITCH SENSE G74 20VT/WT 8 GROUND Z928 20BK/LG Component Location - 53 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Latch-Door-Driver > Page 9241 Power Door Lock Actuator: Locations Latch-Door-Left Rear Component ID: 138 Component : LATCH-DOOR-LEFT REAR Connector: Name : LATCH-DOOR-LEFT REAR Color : BLACK # of pins : 4 Qualifier : (LHD BASE) Pin Description Circuit 1-2-3 LEFT REAR DOOR AJAR SWITCH SENSE G77 20VT/GY 4 GROUND Z928 20BK/LG Component Location - 55 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Latch-Door-Driver > Page 9242 Connector: Name : LATCH-DOOR-LEFT REAR Color : BLACK # of pins : 4 Qualifier : (LHD EXCEPT BASE) Pin Description Circuit 1 PASSENGER DOOR UNLOCK DRIVER P240 20TN/WT 2 DOOR LOCK DRIVER P33 20TN/DB 3 LEFT REAR DOOR AJAR SWITCH SENSE G77 20VT/GY 4 GROUND Z928 20BK/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Latch-Door-Driver > Page 9243 Component Location - 55 Connector: Name : LATCH-DOOR-LEFT REAR Color : # of pins : 8 Qualifier : (RHD) Pin Description Circuit 1-- Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Latch-Door-Driver > Page 9244 2-3 SECONDARY UNLOCK DRIVER P237 20DG/TN 4 SECONDARY LOCK DRIVER P235 20LG/TN 5 PASSENGER DOOR UNLOCK DRIVER P240 20TN/WT 6 DOOR LOCK DRIVER P33 20TN/DB 7 LEFT REAR DOOR AJAR SWITCH SENSE G77 20VT/GY 8 GROUND Z929 20BK/PK Component Location - 55 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Latch-Door-Driver > Page 9245 Power Door Lock Actuator: Locations Latch-Door-Liftgate Component ID: 139 Component : LATCH-DOOR-LIFTGATE Connector: Name : LATCH-DOOR-LIFTGATE C1 Color : BLACK # of pins : 3 Pin Description Circuit 1 DOOR LOCK DRIVER P33 20LG/TN 2-3 PASSENGER DOOR UNLOCK DRIVER P240 20TN/WT Component Location - 67 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Latch-Door-Driver > Page 9246 Connector: Name : LATCH-DOOR-LIFTGATE C2 Color : WHITE # of pins : 2 Pin Description Circuit 1 LIFTGATE AJAR SWITCH SENSE G78 20VT/OR 2 GROUND Z960 18BK/LB Component Location - 67 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Latch-Door-Driver > Page 9247 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Latch-Door-Driver > Page 9248 Power Door Lock Actuator: Locations Latch-Door-Passenger Component ID: 140 Component : LATCH-DOOR-PASSENGER Connector: Name : LATCH-DOOR-PASSENGER Color : # of pins : 4 Qualifier : (LHD BASE) Pin Description Circuit 1-2-3 RIGHT FRONT DOOR AJAR SWITCH SENSE G74 20VT/WT 4 GROUND Z960 20BK/LB Component Location - 53 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Latch-Door-Driver > Page 9249 Connector: Name : LATCH-DOOR-PASSENGER Color : # of pins : 4 Qualifier : (LHD EXCEPT BASE) Pin Description Circuit 1 PASSENGER DOOR UNLOCK DRIVER P240 20TN/WT 2 DOOR LOCK DRIVER P33 20TN/DB 3 RIGHT FRONT DOOR AJAR SWITCH SENSE G74 20VT/WT 4 GROUND Z960 20BK/LB Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Latch-Door-Driver > Page 9250 Component Location - 53 Connector: Name : LATCH-DOOR-PASSENGER Color : # of pins : 8 Qualifier : (RHD) Pin Description Circuit 1-- Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Latch-Door-Driver > Page 9251 2-3 SECONDARY UNLOCK DRIVER P237 20DG/TN 4 SECONDARY LOCK DRIVER P235 20LG/TN 5 PASSENGER DOOR UNLOCK DRIVER P240 20TN/WT 6 DOOR LOCK DRIVER P33 20TN/DB 7 LEFT FRONT DOOR AJAR SWITCH SENSE G75 20VT/DB 8 GROUND Z960 20BK/LB Component Location - 53 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Latch-Door-Driver > Page 9252 Power Door Lock Actuator: Locations Latch-Door-Right Rear Component ID: 141 Component : LATCH-DOOR-RIGHT REAR Connector: Name : LATCH-DOOR-RIGHT REAR Color : # of pins : 4 Qualifier : (LHD BASE) Pin Description Circuit 1-2-3 RIGHT REAR DOOR AJAR SWITCH SENSE G76 20VT/YL 4 GROUND Z928 20BK/LG Component Location - 55 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Latch-Door-Driver > Page 9253 Connector: Name : LATCH-DOOR-RIGHT REAR Color : # of pins : 4 Qualifier : (LHD EXCEPT BASE) Pin Description Circuit 1 PASSENGER DOOR UNLOCK DRIVER P240 20TN/WT 2 DOOR LOCK DRIVER P33 20TN/DB 3 RIGHT REAR DOOR AJAR SWITCH SENSE G76 20VT/YL 4 GROUND Z928 20BK/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Latch-Door-Driver > Page 9254 Component Location - 55 Connector: Name : LATCH-DOOR-RIGHT REAR Color : # of pins : 8 Qualifier : (RHD) Pin Description Circuit 1-- Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Latch-Door-Driver > Page 9255 2-3 SECONDARY UNLOCK DRIVER P237 20DG/TN 4 SECONDARY LOCK DRIVER P235 20LG/TN 5 PASSENGER DOOR UNLOCK DRIVER P240 20TN/WT 6 DOOR LOCK DRIVER P33 20TN/DB 7 RIGHT REAR DOOR AJAR SWITCH SENSE G76 20VT/YL 8 GROUND Z928 20BK/LG Component Location - 55 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Latch-Door-Driver Power Door Lock Actuator: Diagrams Latch-Door-Driver Component ID: 137 Component : LATCH-DOOR-DRIVER Connector: Name : LATCH-DOOR-DRIVER Color : BLACK # of pins : 4 Qualifier : (LHD BASE) Pin Description Circuit 1-2-3 LEFT FRONT DOOR AJAR SWITCH SENSE G75 20VT/DB 4 GROUND Z928 20BK/LG Component Location - 53 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Latch-Door-Driver > Page 9258 Connector: Name : LATCH-DOOR-DRIVER Color : BLACK # of pins : 4 Qualifier : (LHD EXCEPT BASE) Pin Description Circuit 1 DRIVER DOOR UNLOCK DRIVER P238 20TN/DG 2 DOOR LOCK DRIVER P33 20TN/DB 3 LEFT FRONT DOOR AJAR SWITCH SENSE G75 20VT/DB 4 GROUND Z928 20BK/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Latch-Door-Driver > Page 9259 Component Location - 53 Connector: Name : LATCH-DOOR-DRIVER Color : # of pins : 8 Qualifier : (RHD) Pin Description Circuit 1-- Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Latch-Door-Driver > Page 9260 2-3 SECONDARY UNLOCK DRIVER P237 20DG/TN 4 SECONDARY LOCK DRIVER P235 20LG/TN 5 DRIVER DOOR UNLOCK DRIVER P238 20TN/RD 6 DOOR LOCK DRIVER P33 20TN/DB 7 RIGHT FRONT DOOR AJAR SWITCH SENSE G74 20VT/WT 8 GROUND Z928 20BK/LG Component Location - 53 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Latch-Door-Driver > Page 9261 Power Door Lock Actuator: Diagrams Latch-Door-Left Rear Component ID: 138 Component : LATCH-DOOR-LEFT REAR Connector: Name : LATCH-DOOR-LEFT REAR Color : BLACK # of pins : 4 Qualifier : (LHD BASE) Pin Description Circuit 1-2-3 LEFT REAR DOOR AJAR SWITCH SENSE G77 20VT/GY 4 GROUND Z928 20BK/LG Component Location - 55 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Latch-Door-Driver > Page 9262 Connector: Name : LATCH-DOOR-LEFT REAR Color : BLACK # of pins : 4 Qualifier : (LHD EXCEPT BASE) Pin Description Circuit 1 PASSENGER DOOR UNLOCK DRIVER P240 20TN/WT 2 DOOR LOCK DRIVER P33 20TN/DB 3 LEFT REAR DOOR AJAR SWITCH SENSE G77 20VT/GY 4 GROUND Z928 20BK/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Latch-Door-Driver > Page 9263 Component Location - 55 Connector: Name : LATCH-DOOR-LEFT REAR Color : # of pins : 8 Qualifier : (RHD) Pin Description Circuit 1-- Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Latch-Door-Driver > Page 9264 2-3 SECONDARY UNLOCK DRIVER P237 20DG/TN 4 SECONDARY LOCK DRIVER P235 20LG/TN 5 PASSENGER DOOR UNLOCK DRIVER P240 20TN/WT 6 DOOR LOCK DRIVER P33 20TN/DB 7 LEFT REAR DOOR AJAR SWITCH SENSE G77 20VT/GY 8 GROUND Z929 20BK/PK Component Location - 55 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Latch-Door-Driver > Page 9265 Power Door Lock Actuator: Diagrams Latch-Door-Liftgate Component ID: 139 Component : LATCH-DOOR-LIFTGATE Connector: Name : LATCH-DOOR-LIFTGATE C1 Color : BLACK # of pins : 3 Pin Description Circuit 1 DOOR LOCK DRIVER P33 20LG/TN 2-3 PASSENGER DOOR UNLOCK DRIVER P240 20TN/WT Component Location - 67 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Latch-Door-Driver > Page 9266 Connector: Name : LATCH-DOOR-LIFTGATE C2 Color : WHITE # of pins : 2 Pin Description Circuit 1 LIFTGATE AJAR SWITCH SENSE G78 20VT/OR 2 GROUND Z960 18BK/LB Component Location - 67 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Latch-Door-Driver > Page 9267 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Latch-Door-Driver > Page 9268 Power Door Lock Actuator: Diagrams Latch-Door-Passenger Component ID: 140 Component : LATCH-DOOR-PASSENGER Connector: Name : LATCH-DOOR-PASSENGER Color : # of pins : 4 Qualifier : (LHD BASE) Pin Description Circuit 1-2-3 RIGHT FRONT DOOR AJAR SWITCH SENSE G74 20VT/WT 4 GROUND Z960 20BK/LB Component Location - 53 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Latch-Door-Driver > Page 9269 Connector: Name : LATCH-DOOR-PASSENGER Color : # of pins : 4 Qualifier : (LHD EXCEPT BASE) Pin Description Circuit 1 PASSENGER DOOR UNLOCK DRIVER P240 20TN/WT 2 DOOR LOCK DRIVER P33 20TN/DB 3 RIGHT FRONT DOOR AJAR SWITCH SENSE G74 20VT/WT 4 GROUND Z960 20BK/LB Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Latch-Door-Driver > Page 9270 Component Location - 53 Connector: Name : LATCH-DOOR-PASSENGER Color : # of pins : 8 Qualifier : (RHD) Pin Description Circuit 1-- Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Latch-Door-Driver > Page 9271 2-3 SECONDARY UNLOCK DRIVER P237 20DG/TN 4 SECONDARY LOCK DRIVER P235 20LG/TN 5 PASSENGER DOOR UNLOCK DRIVER P240 20TN/WT 6 DOOR LOCK DRIVER P33 20TN/DB 7 LEFT FRONT DOOR AJAR SWITCH SENSE G75 20VT/DB 8 GROUND Z960 20BK/LB Component Location - 53 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Latch-Door-Driver > Page 9272 Power Door Lock Actuator: Diagrams Latch-Door-Right Rear Component ID: 141 Component : LATCH-DOOR-RIGHT REAR Connector: Name : LATCH-DOOR-RIGHT REAR Color : # of pins : 4 Qualifier : (LHD BASE) Pin Description Circuit 1-2-3 RIGHT REAR DOOR AJAR SWITCH SENSE G76 20VT/YL 4 GROUND Z928 20BK/LG Component Location - 55 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Latch-Door-Driver > Page 9273 Connector: Name : LATCH-DOOR-RIGHT REAR Color : # of pins : 4 Qualifier : (LHD EXCEPT BASE) Pin Description Circuit 1 PASSENGER DOOR UNLOCK DRIVER P240 20TN/WT 2 DOOR LOCK DRIVER P33 20TN/DB 3 RIGHT REAR DOOR AJAR SWITCH SENSE G76 20VT/YL 4 GROUND Z928 20BK/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Latch-Door-Driver > Page 9274 Component Location - 55 Connector: Name : LATCH-DOOR-RIGHT REAR Color : # of pins : 8 Qualifier : (RHD) Pin Description Circuit 1-- Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Latch-Door-Driver > Page 9275 2-3 SECONDARY UNLOCK DRIVER P237 20DG/TN 4 SECONDARY LOCK DRIVER P235 20LG/TN 5 PASSENGER DOOR UNLOCK DRIVER P240 20TN/WT 6 DOOR LOCK DRIVER P33 20TN/DB 7 RIGHT REAR DOOR AJAR SWITCH SENSE G76 20VT/YL 8 GROUND Z928 20BK/LG Component Location - 55 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Description and Operation > Description Power Door Lock Actuator: Description and Operation Description DESCRIPTION The lock mechanisms are actuated by a reversible electric motor mounted within each door and tailgate. The power lock motors are integral to the door latch units. The power lock motors cannot be adjusted or repaired and, if inoperative or damaged, the door latch unit must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Description and Operation > Description > Page 9278 Power Door Lock Actuator: Description and Operation Operation OPERATION The door lock motors are controlled by relays. A positive and negative battery connection to the two motor terminals will cause the motor to move in one direction. Reversing the current will cause the motor to move in the opposite direction. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Description and Operation > Page 9279 Power Door Lock Actuator: Testing and Inspection DOOR LOCK MOTOR The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic information. Refer to the appropriate wiring information. 1. Make certain battery is in normal condition and fuses powering the RKE module aren't blown before circuits are tested. 2. To determine which motor is inoperative, check each individual door for electrical lock and unlock or disconnect the motor connectors one at a time, while operating the door lock switch. 3. In the event that none of the motors work, the problem maybe caused by a shorted motor, a bad switch or a bad relay internal to the RKE module. Disconnecting a defective motor will allow the others to work. 4. To test an individual door lock motor, disconnect the electrical connector from the motor. 5. To lock the door, connect a 12 volt power source to one pin of the lock motor and a ground wire to the other pin. 6. To unlock the door, reverse the wire connections at the motor pin terminals. 7. If these results are NOT obtained, replace the motor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Removal Power Door Lock Actuator: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove liftgate trim panel. 3. Disconnect motor wire harness connector. 4. Remove liftgate lock motor (2) from liftgate by gently unsnapping. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Removal > Page 9282 Power Door Lock Actuator: Service and Repair Installation INSTALLATION 1. Install liftgate lock motor (2) on the liftgate. 2. Install motor wire harness connector. 3. Install the liftgate trim panel. 4. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection Power Door Lock Switch: Testing and Inspection DOOR LOCK SWITCH 1. Remove the switch. 2. Using an ohmmeter, refer to Door Lock Switch Test table to determine if switch resistance is correct in the Lock and Unlock switch positions. Refer to Wiring Diagrams for harness connector pin-outs. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Service and Repair > Removal Power Door Lock Switch: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the front door bolster. 3. Disconnect the electrical harness connectors. 4. With the bolster on the bench, gently pry in on the tabs of the mirror switch and push through the front of the cover and remove. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Service and Repair > Removal > Page 9288 Power Door Lock Switch: Service and Repair Installation INSTALLATION 1. Place the mirror switch in bolster opening and firmly snap into place. 2. Connect the electrical harness connectors. 3. Install the front door bolster. 4. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations Power Mirror Switch: Locations Component ID: 346 Component : SWITCH-MIRROR Connector: Name : SWITCH-MIRROR Color : BLACK # of pins : 10 Qualifier : (LHD) Pin Description Circuit 1-2-3 MIRROR COMMON DRIVER P76 20YL/PK 4 GROUND Z928 20BK/LG 5 FUSED B(+) (I.O.D.) A417 20RD/DG 6 RIGHT MIRROR VERTICAL DRIVER P72 20TN/GY 7 LEFT MIRROR VERTICAL DRIVER P71 20TN/DG 8 RIGHT MIRROR HORIZONTAL DRIVER P74 20TN/OR 9 LEFT MIRROR HORIZONTAL DRIVER P75 20TN/OR 10 - Component Location - 54 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 9293 Connector: Name : SWITCH-MIRROR Color : # of pins : 10 Qualifier : (RHD) Pin Description Circuit 1 FOLDING MIRROR RETURN P110 20LG/WT 2-3 MIRROR COMMON DRIVER P76 20YL/PK 4 GROUND Z928 20BK/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 9294 5 FUSED B(+) (I.O.D.) A417 20RD/DG 6 RIGHT MIRROR VERTICAL DRIVER P72 20TN/GY 7 LEFT MIRROR VERTICAL DRIVER P71 20TN/DG 8 RIGHT MIRROR HORIZONTAL DRIVER P74 20TN/OR 9 LEFT MIRROR HORIZONTAL DRIVER P75 20TN/OR 10 MIRROR-POWER FOLDING/UNFOLDING P699 20LG/DG Component Location - 54 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 9295 Power Mirror Switch: Diagrams Component ID: 346 Component : SWITCH-MIRROR Connector: Name : SWITCH-MIRROR Color : BLACK # of pins : 10 Qualifier : (LHD) Pin Description Circuit 1-2-3 MIRROR COMMON DRIVER P76 20YL/PK 4 GROUND Z928 20BK/LG 5 FUSED B(+) (I.O.D.) A417 20RD/DG 6 RIGHT MIRROR VERTICAL DRIVER P72 20TN/GY 7 LEFT MIRROR VERTICAL DRIVER P71 20TN/DG 8 RIGHT MIRROR HORIZONTAL DRIVER P74 20TN/OR 9 LEFT MIRROR HORIZONTAL DRIVER P75 20TN/OR 10 - Component Location - 54 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 9296 Connector: Name : SWITCH-MIRROR Color : # of pins : 10 Qualifier : (RHD) Pin Description Circuit 1 FOLDING MIRROR RETURN P110 20LG/WT 2-3 MIRROR COMMON DRIVER P76 20YL/PK 4 GROUND Z928 20BK/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 9297 5 FUSED B(+) (I.O.D.) A417 20RD/DG 6 RIGHT MIRROR VERTICAL DRIVER P72 20TN/GY 7 LEFT MIRROR VERTICAL DRIVER P71 20TN/DG 8 RIGHT MIRROR HORIZONTAL DRIVER P74 20TN/OR 9 LEFT MIRROR HORIZONTAL DRIVER P75 20TN/OR 10 MIRROR-POWER FOLDING/UNFOLDING P699 20LG/DG Component Location - 54 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 9298 Power Mirror Switch: Testing and Inspection POWER MIRROR SWITCH - LHD 1. Disconnect and isolate the battery negative cable. 2. Remove power mirror switch. 3. Using an ohmmeter, test for continuity between the terminals of the switch as shown in the Mirror Switch Test table. 4. If test results are not obtained as shown in the Mirror Switch Test table, replace the switch. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 9299 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 9300 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Service and Repair > Removal Power Mirror Switch: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the front door bolster. 3. Disconnect the electrical harness connectors. 4. With the bolster on the bench, gently pry in on the tabs of the mirror switch and push through the front of the cover and remove. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Service and Repair > Removal > Page 9303 Power Mirror Switch: Service and Repair Installation INSTALLATION 1. Place the mirror switch in bolster opening and firmly snap into place. 2. Connect the electrical harness connectors. 3. Install the front door bolster. 4. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest for Paint: > 23-046-07 > Oct > 07 > Body - Horizontal Paint Surface Etching Paint: Customer Interest Body - Horizontal Paint Surface Etching NUMBER: 23-046-07 GROUP: Body DATE: October 30, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-003-06, DATED JANUARY 19, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL YEARS AND MODELS. SUBJECT: Paint Repair - Etching OVERVIEW: This bulletin involves evaluating the paint condition on all horizontal panels for etching and using the procedures listed in the Paint Condition Deck p/n 81-316-0507 or using the information listed in this bulletin MODELS: 2006 - (CS) Pacifica **2008** 2006 - (DR/D1/DC/DH) Ram Truck **2008** 2006 - (HB) Durango **2008** **2007 - 2008 (HG) Aspen** 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan **2007 - 2008 (JS) Sebring/Sebring Convertible/Avenger** **2007 - 2008 (JK) Wrangler** **2007 - 2008 (KA) Nitro** 2006- (KJ) Liberty **2007** **2008 (KK) Liberty 2006 - (LX) 300/Magnum/**Charger** **2008** **2007 - 2008 (MK) Compass/Patriot** 2006- (ND) Dakota **2008** **2007 - 2008 (PM) Caliber** 2006 - (RS) Town & Country/Caravan **2007** **2008 (RI) Town & Country/Grand Caravan** 2006 (TJ) Wrangler 2005 - (WK) Grand Cherokee **2008** 2006 - (XK) Commander Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest for Paint: > 23-046-07 > Oct > 07 > Body - Horizontal Paint Surface Etching > Page 9313 **2008** DIAGNOSIS: Inspect the vehicle horizontal panels for the appearance of an etched surface (picture available in "PAINT CONDITION DECK" - publication number 81-316-0507 - see "INSECT ETCH" graphic). Two procedures are available depending on the severity of the condition. Repair Procedure "A" is for conditions that do not show through to primer and Repair Procedure "B" is for conditions that show primer within the etch area. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE "A" FINESSE: 1. Clean with Mopar Car Wash Concentrate, and water. 2. Wipe with an alcohol based cleaner 3. Evaluate the paint condition. 4. Measure and record paint film thickness in areas to be sanded using an electronic mil gauge (PSE). 5. Use 2000 grit sand paper mounted to a ridged backer to remove all etching. 6. If you remove more than 0.5 mil of clear coat you will need to refinish using repair procedure "B" refinish. 7. If refinishing is not required polish sanded areas using Mopar Compound Power Cleaner # BSMM8432. 8. Remove swirl marks using Mopar Swirl Free polish # BSMM8232. 9. Detail vehicle as required. REPAIR PROCEDURE "B" REFINISH: 1. Clean with Mopar Car Wash Concentrate, and water. 2. Wipe with an alcohol based cleaner 3. Evaluate the paint condition. 4. DA surface with 600 grit sand paper. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest for Paint: > 23-046-07 > Oct > 07 > Body - Horizontal Paint Surface Etching > Page 9314 5. Clean with appropriate solvent per paint supplier recommendations. 6. Feather edge the damaged areas. 7. Apply corrosion resistant primer to bare metal spots if they exist. 8. Spot prime with primer surfacer. 9. Block sand the primer surfacer. 10. Final sand per paint suppliers recommendations. 11. Clean with appropriate solvent. 12. Tack off the repair area. 13. Apply basecoat with appropriate hardener per paint supplier recommendations. 14. Allow flash time per paint suppliers recommendations and tack off area. 15. Apply clear coat per paint suppliers recommendations. 16. Detail vehicle as required. NOTE: No clear coat spot Repair should be performed on class "A" surfaces. POLICY: Reimbursable within the provisions of the warranty. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest for Paint: > 23-046-07 > Oct > 07 > Body - Horizontal Paint Surface Etching > Page 9315 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 23-046-07 > Oct > 07 > Body - Horizontal Paint Surface Etching Paint: All Technical Service Bulletins Body - Horizontal Paint Surface Etching NUMBER: 23-046-07 GROUP: Body DATE: October 30, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-003-06, DATED JANUARY 19, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL YEARS AND MODELS. SUBJECT: Paint Repair - Etching OVERVIEW: This bulletin involves evaluating the paint condition on all horizontal panels for etching and using the procedures listed in the Paint Condition Deck p/n 81-316-0507 or using the information listed in this bulletin MODELS: 2006 - (CS) Pacifica **2008** 2006 - (DR/D1/DC/DH) Ram Truck **2008** 2006 - (HB) Durango **2008** **2007 - 2008 (HG) Aspen** 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan **2007 - 2008 (JS) Sebring/Sebring Convertible/Avenger** **2007 - 2008 (JK) Wrangler** **2007 - 2008 (KA) Nitro** 2006- (KJ) Liberty **2007** **2008 (KK) Liberty 2006 - (LX) 300/Magnum/**Charger** **2008** **2007 - 2008 (MK) Compass/Patriot** 2006- (ND) Dakota **2008** **2007 - 2008 (PM) Caliber** 2006 - (RS) Town & Country/Caravan **2007** **2008 (RI) Town & Country/Grand Caravan** 2006 (TJ) Wrangler 2005 - (WK) Grand Cherokee **2008** 2006 - (XK) Commander Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 23-046-07 > Oct > 07 > Body - Horizontal Paint Surface Etching > Page 9321 **2008** DIAGNOSIS: Inspect the vehicle horizontal panels for the appearance of an etched surface (picture available in "PAINT CONDITION DECK" - publication number 81-316-0507 - see "INSECT ETCH" graphic). Two procedures are available depending on the severity of the condition. Repair Procedure "A" is for conditions that do not show through to primer and Repair Procedure "B" is for conditions that show primer within the etch area. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE "A" FINESSE: 1. Clean with Mopar Car Wash Concentrate, and water. 2. Wipe with an alcohol based cleaner 3. Evaluate the paint condition. 4. Measure and record paint film thickness in areas to be sanded using an electronic mil gauge (PSE). 5. Use 2000 grit sand paper mounted to a ridged backer to remove all etching. 6. If you remove more than 0.5 mil of clear coat you will need to refinish using repair procedure "B" refinish. 7. If refinishing is not required polish sanded areas using Mopar Compound Power Cleaner # BSMM8432. 8. Remove swirl marks using Mopar Swirl Free polish # BSMM8232. 9. Detail vehicle as required. REPAIR PROCEDURE "B" REFINISH: 1. Clean with Mopar Car Wash Concentrate, and water. 2. Wipe with an alcohol based cleaner 3. Evaluate the paint condition. 4. DA surface with 600 grit sand paper. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 23-046-07 > Oct > 07 > Body - Horizontal Paint Surface Etching > Page 9322 5. Clean with appropriate solvent per paint supplier recommendations. 6. Feather edge the damaged areas. 7. Apply corrosion resistant primer to bare metal spots if they exist. 8. Spot prime with primer surfacer. 9. Block sand the primer surfacer. 10. Final sand per paint suppliers recommendations. 11. Clean with appropriate solvent. 12. Tack off the repair area. 13. Apply basecoat with appropriate hardener per paint supplier recommendations. 14. Allow flash time per paint suppliers recommendations and tack off area. 15. Apply clear coat per paint suppliers recommendations. 16. Detail vehicle as required. NOTE: No clear coat spot Repair should be performed on class "A" surfaces. POLICY: Reimbursable within the provisions of the warranty. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 23-046-07 > Oct > 07 > Body - Horizontal Paint Surface Etching > Page 9323 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 9324 Paint: By Symptom Technical Service Bulletin # 23-046-07 Date: 071030 Body - Horizontal Paint Surface Etching NUMBER: 23-046-07 GROUP: Body DATE: October 30, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-003-06, DATED JANUARY 19, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL YEARS AND MODELS. SUBJECT: Paint Repair - Etching OVERVIEW: This bulletin involves evaluating the paint condition on all horizontal panels for etching and using the procedures listed in the Paint Condition Deck p/n 81-316-0507 or using the information listed in this bulletin MODELS: 2006 - (CS) Pacifica **2008** 2006 - (DR/D1/DC/DH) Ram Truck **2008** 2006 - (HB) Durango **2008** **2007 - 2008 (HG) Aspen** 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan **2007 - 2008 (JS) Sebring/Sebring Convertible/Avenger** **2007 - 2008 (JK) Wrangler** **2007 - 2008 (KA) Nitro** 2006- (KJ) Liberty **2007** **2008 (KK) Liberty 2006 - (LX) 300/Magnum/**Charger** **2008** **2007 - 2008 (MK) Compass/Patriot** 2006- (ND) Dakota **2008** **2007 - 2008 (PM) Caliber** 2006 - (RS) Town & Country/Caravan **2007** **2008 (RI) Town & Country/Grand Caravan** 2006 (TJ) Wrangler 2005 - (WK) Grand Cherokee Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 9325 **2008** 2006 - (XK) Commander **2008** DIAGNOSIS: Inspect the vehicle horizontal panels for the appearance of an etched surface (picture available in "PAINT CONDITION DECK" - publication number 81-316-0507 - see "INSECT ETCH" graphic). Two procedures are available depending on the severity of the condition. Repair Procedure "A" is for conditions that do not show through to primer and Repair Procedure "B" is for conditions that show primer within the etch area. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE "A" FINESSE: 1. Clean with Mopar Car Wash Concentrate, and water. 2. Wipe with an alcohol based cleaner 3. Evaluate the paint condition. 4. Measure and record paint film thickness in areas to be sanded using an electronic mil gauge (PSE). 5. Use 2000 grit sand paper mounted to a ridged backer to remove all etching. 6. If you remove more than 0.5 mil of clear coat you will need to refinish using repair procedure "B" refinish. 7. If refinishing is not required polish sanded areas using Mopar Compound Power Cleaner # BSMM8432. 8. Remove swirl marks using Mopar Swirl Free polish # BSMM8232. 9. Detail vehicle as required. REPAIR PROCEDURE "B" REFINISH: 1. Clean with Mopar Car Wash Concentrate, and water. 2. Wipe with an alcohol based cleaner 3. Evaluate the paint condition. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 9326 4. DA surface with 600 grit sand paper. 5. Clean with appropriate solvent per paint supplier recommendations. 6. Feather edge the damaged areas. 7. Apply corrosion resistant primer to bare metal spots if they exist. 8. Spot prime with primer surfacer. 9. Block sand the primer surfacer. 10. Final sand per paint suppliers recommendations. 11. Clean with appropriate solvent. 12. Tack off the repair area. 13. Apply basecoat with appropriate hardener per paint supplier recommendations. 14. Allow flash time per paint suppliers recommendations and tack off area. 15. Apply clear coat per paint suppliers recommendations. 16. Detail vehicle as required. NOTE: No clear coat spot Repair should be performed on class "A" surfaces. POLICY: Reimbursable within the provisions of the warranty. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 9327 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 23-046-07 Date: 071030 Body - Horizontal Paint Surface Etching NUMBER: 23-046-07 GROUP: Body DATE: October 30, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-003-06, DATED JANUARY 19, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL YEARS AND MODELS. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 9328 SUBJECT: Paint Repair - Etching OVERVIEW: This bulletin involves evaluating the paint condition on all horizontal panels for etching and using the procedures listed in the Paint Condition Deck p/n 81-316-0507 or using the information listed in this bulletin MODELS: 2006 - (CS) Pacifica **2008** 2006 - (DR/D1/DC/DH) Ram Truck **2008** 2006 - (HB) Durango **2008** **2007 - 2008 (HG) Aspen** 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan **2007 - 2008 (JS) Sebring/Sebring Convertible/Avenger** **2007 - 2008 (JK) Wrangler** **2007 - 2008 (KA) Nitro** 2006- (KJ) Liberty **2007** **2008 (KK) Liberty 2006 - (LX) 300/Magnum/**Charger** **2008** **2007 - 2008 (MK) Compass/Patriot** 2006- (ND) Dakota **2008** **2007 - 2008 (PM) Caliber** 2006 - (RS) Town & Country/Caravan **2007** **2008 (RI) Town & Country/Grand Caravan** 2006 (TJ) Wrangler 2005 - (WK) Grand Cherokee **2008** 2006 - (XK) Commander **2008** DIAGNOSIS: Inspect the vehicle horizontal panels for the appearance of an etched surface (picture available in "PAINT CONDITION DECK" - publication number 81-316-0507 - see "INSECT ETCH" graphic). Two procedures are available depending on the severity of the condition. Repair Procedure "A" is for conditions that do not show through to primer and Repair Procedure "B" is for conditions that show primer within the etch area. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 9329 PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE "A" FINESSE: 1. Clean with Mopar Car Wash Concentrate, and water. 2. Wipe with an alcohol based cleaner 3. Evaluate the paint condition. 4. Measure and record paint film thickness in areas to be sanded using an electronic mil gauge (PSE). 5. Use 2000 grit sand paper mounted to a ridged backer to remove all etching. 6. If you remove more than 0.5 mil of clear coat you will need to refinish using repair procedure "B" refinish. 7. If refinishing is not required polish sanded areas using Mopar Compound Power Cleaner # BSMM8432. 8. Remove swirl marks using Mopar Swirl Free polish # BSMM8232. 9. Detail vehicle as required. REPAIR PROCEDURE "B" REFINISH: 1. Clean with Mopar Car Wash Concentrate, and water. 2. Wipe with an alcohol based cleaner 3. Evaluate the paint condition. 4. DA surface with 600 grit sand paper. 5. Clean with appropriate solvent per paint supplier recommendations. 6. Feather edge the damaged areas. 7. Apply corrosion resistant primer to bare metal spots if they exist. 8. Spot prime with primer surfacer. 9. Block sand the primer surfacer. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 9330 10. Final sand per paint suppliers recommendations. 11. Clean with appropriate solvent. 12. Tack off the repair area. 13. Apply basecoat with appropriate hardener per paint supplier recommendations. 14. Allow flash time per paint suppliers recommendations and tack off area. 15. Apply clear coat per paint suppliers recommendations. 16. Detail vehicle as required. NOTE: No clear coat spot Repair should be performed on class "A" surfaces. POLICY: Reimbursable within the provisions of the warranty. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 9331 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes Paint: Application and ID Paint Codes DODGE CALIBER PAINT CODES Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 9334 Paint: Application and ID Paint Code Location DODGE CALIBER PAINT CODE LOCATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Page 9335 Paint: Description and Operation DESCRIPTION On most vehicles a two-part paint application (basecoat/clearcoat) is used. Color paint that is applied to primer is called basecoat. The clearcoat protects the basecoat from ultraviolet light and provides a durable high-gloss finish. CAUTION: Do not use abrasive chemicals or compounds on painted surfaces. Damage to finish can result. Do not use harsh alkaline based cleaning solvents on painted surfaces. Damage to finish or color can result. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Paint Touch-Up Paint: Service and Repair Paint Touch-Up DESCRIPTION When a painted metal surface has been scratched or chipped, it should be touched up as soon as possible to avoid corrosion. For best results, use Mopar(R) Scratch Filler/Primer, Touch Up Paints and Clear Top Coat. WARNING: Use an OSHA approved respirator and safety glasses when spraying paint or solvents in a confined area. Personal injury can result. TOUCH UP PROCEDURE 1. Scrape loose paint and corrosion from inside scratch or chip. 2. Clean affected area with Mopar(R) Tar/Road Oil Remover, and allow to dry. 3. Fill the inside of the scratch or chip with a coat of filler/primer. Do not overlap primer onto good surface finish. The applicator brush should be wet enough to puddle-fill the scratch or chip without running. Do not stroke brush applicator on body surface. Allow the filler/primer to dry hard. 4. Cover the filler/primer with color touch up paint. Do not overlap touch up color onto the original color coat around the scratch or chip. Butt the new color to the original color, if possible. Do not stroke applicator brush on body surface. Allow touch up paint to dry hard. 5. On vehicles without clearcoat, the touch up color can be lightly finesse sanded (1500 grit) and polished with rubbing compound. 6. On vehicles with clearcoat, apply clear top coat to touch up paint with the same technique as described in STEP 4. Allow clear top coat to dry hard. If desired, STEP 5 can be performed on clear top coat. WARNING: Avoid prolonged skin contact with petroleum or alcohol - based cleaning solvents. Personal injury can result. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Paint Touch-Up > Page 9338 Paint: Service and Repair Finesse Sanding, Buffing, And Polishing - Description DESCRIPTION Minor acid etching, orange peel, or smudging in clearcoat or single-stage finishes can be reduced with light finesse sanding, hand buffing, and polishing. If the finish has been finesse sanded in the past, it cannot be repeated. Finesse sanding operation should be performed by a trained automotive paint technician. CAUTION: Do not remove clearcoat finish, if equipped. Basecoat paint must retain clearcoat for durability. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Radiator Support > Component Information > Service and Repair > Removal Radiator Support: Service and Repair Removal REMOVAL 1. Rotate the two retaining clips (3) and remove the air cleaner snorkel (2) from air cleaner box (1). 2. Remove fascia fasteners (1). 3. Remove closure panel fasteners (2). 4. Remove closure panel from vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Radiator Support > Component Information > Service and Repair > Removal > Page 9343 Radiator Support: Service and Repair Installation INSTALLATION 1. Slide closure panel under fascia aligning holes. 2. Tighten fascia fasteners (1). 3. Insert closure panel fasteners (2) and tighten. 4. Insert air cleaner snorkel into airbox opening. Rotate the two retaining clips (3) and fasten into closure panel ensuring fit. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Component ID: 161 Component : MODULE-SENTRY KEY REMOTE ENTRY/WCM Connector: Name : MODULE-SENTRY KEY REMOTE ENTRY/WCM Color : BLACK # of pins : 8 Pin Description Circuit 1 IGNITION SWITCH SENSE G20 20VT/BR 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4 GROUND Z937 20BK/YL 5 FUSED B(+) (I.O.D.) A411 20RD/LG 6 CAN B BUS (+) D55 20WT/OR 7 CAN B BUS (-) D54 20WT/PK 8-Component Location - 28 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 9348 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 9349 Keyless Entry Module: Diagrams Component ID: 161 Component : MODULE-SENTRY KEY REMOTE ENTRY/WCM Connector: Name : MODULE-SENTRY KEY REMOTE ENTRY/WCM Color : BLACK # of pins : 8 Pin Description Circuit 1 IGNITION SWITCH SENSE G20 20VT/BR 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4 GROUND Z937 20BK/YL 5 FUSED B(+) (I.O.D.) A411 20RD/LG 6 CAN B BUS (+) D55 20WT/OR 7 CAN B BUS (-) D54 20WT/PK 8-Component Location - 28 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 9350 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Description and Operation > Description Keyless Entry Module: Description and Operation Description DESCRIPTION When a PCM and the SKREEM are replaced at the same time, perform the following steps in order: 1. Program the new PCM. 2. Program the new SKREEM. 3. Replace all ignition keys and program them to the new SKREEM. The Sentry Key REmote Entry Module (SKREEM) is sometimes referred to as the Wireless Control Module (WCM). The SKREEM/WCM is the primary component of the Sentry Key Immobilizer System (SKIS). It is also the receiver for the Remote Keyless Entry (RKE) system and the Tire Pressure Monitor (TPM) system. The SKREEM/WCM is located on the steering column, around the ignition lock cylinder housing and is concealed beneath the steering column shrouds. The molded black plastic housing for the SKREEM/WCM has an integral molded plastic halo-like antenna ring (3) that extends from one side. When the SKREEM/WCM is properly installed, the antenna ring is oriented around the ignition lock cylinder housing. A single connector (4) is located next to the antenna ring on the SKREEM/WCM housing (3). A molded plastic mounting tab (2) on the SKREEM/WCM housing secures the unit to the steering column. The SKREEM/WCM is connected to the vehicle electrical system through the instrument panel wire harness. The SKREEM/WCM cannot be adjusted or repaired. If faulty or damaged, the entire SKREEM unit must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Description and Operation > Description > Page 9353 Keyless Entry Module: Description and Operation Operation OPERATION The Sentry Key REmote Entry Module (SKREEM), sometimes referred to as the Wireless Control Module (WCM), contains a Radio Frequency (RF) transceiver and a microprocessor. The SKREEM/WCM transmits RF signals to, and receives RF signals from the Sentry Key transponder through a tuned antenna enclosed within the molded plastic antenna ring integral to the SKREEM/WCM housing. If this antenna ring is not mounted properly around the ignition lock cylinder housing, communication problems between the SKREEM/WCM and the transponder may arise. These communication problems will result in Sentry Key transponder-related faults. The SKREEM also serves as the Remote Keyless Entry (RKE) RF receiver and, if the vehicle is so equipped, the receiver for the Tire Pressure Monitoring (TPM) system. The SKREEM/WCM communicates over the Controller Area Network (CAN) data bus with the Electromechanical Instrument Cluster (EMIC) (sometimes referred to as the Cab Compartment Node (CCN), the Powertrain Control Module (PCM), and/or the diagnostic scan tool. The SKREEM/WCM retains in memory the ID numbers of any Sentry Key transponder that is programmed into it. A maximum of eight Sentry Key transponders can be programmed into the SKREEM/WCM. For added system security, each SKREEM/WCM is programmed with a unique Secret Key code. This code is stored in memory, sent over the CAN data bus to the PCM, and is encoded to the transponder of every Sentry Key that is programmed into the SKREEM/WCM. Therefore, the Secret Key code is a common element that is found in every component of the Sentry Key Immobilizer System (SKIS). Another security code, called a PIN, is used to gain access to the SKREEM/WCM Secured Access Mode. The Secured Access Mode is required during service to perform the SKIS initialization and Sentry Key transponder programming procedures. The SKREEM/WCM also stores the Vehicle Identification Number (VIN) in its memory, which it learns through a CAN data bus message from the PCM during SKIS initialization. NOTE: After a SKREEM/WCM is replaced, the ignition/transponder keys need to be programmed to the new SKREEM/WCM. Follow the directions on the diagnostic scan tool. The transponder key for the SKREES/SKIM and the RKE will both be programmed during this operation. There is no need to program the fob of the key for RKE functionality once the transponder key is programmed to the new SKREEM/WCM. In the event that a SKREEM/WCM replacement is required, the Secret Key code can be transferred to the new SKREEM/WCM from the PCM using the diagnostic scan tool and the SKIS initialization procedure. Proper completion of the SKIS initialization will allow the existing Sentry Keys to be programmed into the new SKREEM/WCM so that new keys will not be required. In the event that the original Secret Key code cannot be recovered, SKREEM/WCM replacement will also require new Sentry Keys. The diagnostic scan tool will alert the technician during the SKIS initialization procedure if new Sentry Keys are required. When the ignition switch is turned to the On position, the SKREEM/WCM transmits an RF signal to the transponder in the ignition key. The SKREEM/WCM then waits for an RF signal response from the transponder. If the response received identifies the key as valid, the SKREEM/WCM sends a valid key message to the PCM over the CAN data bus. If the response received identifies the key as invalid or if no response is received from the key transponder, the SKREEM/WCM sends an invalid key message to the PCM. The PCM will enable or disable engine operation based upon the status of the SKREEM/WCM messages. It is important to note that the default condition in the PCM is an invalid key; therefore, if no message is received from the SKREEM/WCM by the PCM, the engine will be disabled and the vehicle immobilized after two seconds of running. The SKREEM/WCM also sends security indicator status messages to the EMIC/CCN over the CAN data bus to tell the EMIC/CCN how to operate the security indicator. The security indicator status message from the SKREEM/WCM tells the EMIC/CCN to turn the indicator on for about three seconds each time the ignition switch is turned to the On position as a bulb test. After completion of the bulb test, the SKREEM/WCM sends security indicator status messages to the EMIC/CCN to turn the indicator off, turn the indicator on, or to flash the indicator on and off. If the security indicator flashes or stays on solid after the bulb test, it signifies a SKIS fault. If the SKREEM/WCM detects a system malfunction and/or the SKIS has become inoperative, the security indicator will stay on solid. If the SKREEM/WCM detects an invalid key or if a key transponder-related fault exists, the security indicator will flash. If the vehicle is equipped with the Customer Learn transponder programming feature, the SKREEM/WCM will also send messages to the EMIC/CCN to flash the security indicator whenever the Customer Learn programming mode is being utilized. The SKIS performs a self-test each time the ignition switch is turned to the On position, and will store fault information in the form of a Diagnostic Trouble Code (DTC) in SKREEM/WCM memory if a system malfunction is detected. The SKREEM/WCM can be diagnosed, and any stored DTC can be retrieved using a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Description and Operation > Page 9354 Keyless Entry Module: Testing and Inspection REMOTE KEYLESS ENTRY MODULE The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic information. Refer to the appropriate wiring information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Removal Keyless Entry Module: Service and Repair Removal REMOVAL NOTE: The steering wheel does not have to be removed to service the SKREEM/WCM. NOTE: The Steering Column Control Module (SCCM) assembly, which consists of the left/right multi-function switches and the clockspring, does not have to be removed to service the SKREEM/WCM. There is an access hole in the top of the right multi-function switch to access the mounting screw (2). 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. 2. Remove the upper and lower steering column shrouds. 3. Remove the SKREEM/WCM mounting screw (2) on the ignition lock assembly and separate the SKREEM/WCM (3) from the ignition lock assembly. 4. Disconnect the SKREEM/WCM electrical connector (4). 5. Remove SKREEM/WCM (1 and 3) from column (2). When a PCM and the SKREEM/WCM are replaced at the same time, perform the following steps in order. - Program the new PCM. - Program the new SKREEM/WCM. - Replace all ignition keys and program them to the new SKREEM/WCM. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Removal > Page 9357 Keyless Entry Module: Service and Repair Installation INSTALLATION When a PCM and the SKREEM/WCM are replaced at the same time, perform the following steps in order. - Program the new PCM. - Program the new SKREEM/WCM. - Replace all ignition keys and program them to the new SKREEM/WCM. 1. Position the SKREEM/WCM (3) on the ignition lock housing and install the retaining screw (2). 2. Connect the SKREEM/WCM electrical connector (4). NOTE: On vehicles equipped with the optional Sentry Key Immobilizer System (SKIS), when the SKREEM is replaced with a new unit, a diagnostic scan tool MUST be used to initialize the new SKREEM and to program at least two Sentry Key transponders before the vehicle can be operated. 3. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations Seat Heater Control Module: Locations Component ID: 155 Component : MODULE-HEATED SEATS Connector: Name : MODULE-HEATED SEATS Color : BLACK # of pins : 10 A-B-C-D LEFT SEAT HEATER B(+) DRIVER P187 16LG/BR D RIGHT SEAT HEATER B(+) DRIVER P188 16LG/BR E FUSED IGNITION SWITCH OUTPUT (RUN) F937 14PK/YL F GROUND Z960 18BK G-- H-J LIN BUS D506 20WT/DG K RIGHT SEAT HEATER B(+) DRIVER P188 16LG/VT K LEFT SEAT HEATER B(+) DRIVER P187 16LG/VT Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Page 9361 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Page 9362 Seat Heater Control Module: Diagrams Component ID: 155 Component : MODULE-HEATED SEATS Connector: Name : MODULE-HEATED SEATS Color : BLACK # of pins : 10 A-B-C-D LEFT SEAT HEATER B(+) DRIVER P187 16LG/BR D RIGHT SEAT HEATER B(+) DRIVER P188 16LG/BR E FUSED IGNITION SWITCH OUTPUT (RUN) F937 14PK/YL F GROUND Z960 18BK G-- H-J LIN BUS D506 20WT/DG K RIGHT SEAT HEATER B(+) DRIVER P188 16LG/VT K LEFT SEAT HEATER B(+) DRIVER P187 16LG/VT Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Page 9363 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation > Description Seat Heater Control Module: Description and Operation Description DESCRIPTION The heated seat module (2) is located under the left front seat. It has a single electrical connector (1) and a push pin style retainer that secures it to the seat pan. The module can be accessed from under the front left seat with the seat in the full back position. The heated seat module is a microprocessor designed to use the Local Interface Network (LIN) data bus messages from the instrument cluster also known as the Cabin Compartment Node (CCN). The CCN receives inputs from the heated seat switches and in turn signals the heated seat module to operate the heated seat elements for both front seats. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation > Description > Page 9366 Seat Heater Control Module: Description and Operation Operation OPERATION The heated seat module operates on fused battery current received from the ignition switch. The module is grounded to the body at all times through the electrical connector. Inputs to the module include Local Interface Network (LIN) data bus messages and standard hardwired 12 volt power and ground. In response to the LIN inputs the heated seat module will control the battery current to the appropriate heated seat elements. When a heated seat switch LIN data bus signal is received by the heated seat module, the module energizes the selected heated seat element. The Low heat set point is about 38° C (100.4° F), and the High heat set point is about 42° C (107.6° F). In addition to operating the heated seat elements, the heated seat module sends LED illumination messages to the CCN via the LIN data bus. The CCN then sends the LED illumination message to the accessory switch bank so that the appropriate LEDs are illuminated for any given heating level. Pressing the switch once will select high-level heating. Pressing the switch a second time will select low-level heating. Pressing the switch a third time will shut the heating elements off. If the heated seat module detects a heated seat element OPEN or SHORT circuit, it will record and store the appropriate diagnostic trouble code (DTC). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation > Page 9367 Seat Heater Control Module: Testing and Inspection HEATED SEAT MODULE In order to obtain conclusive testing, the heated seat system and the Local Interface Network (LIN) data bus circuit must be checked. Any diagnosis of the heated seat system should begin with the use of a scan tool. Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. NOTE: Vehicles equipped with the heated seat option utilize a low voltage cut-off feature. This feature turns off power to the heated seat system anytime vehicle voltage is below 11.7v or above 15.5v. Be certain to check the vehicle electrical system for proper voltage anytime the power seat system appears inoperative. Before any testing of the heated seat system is attempted, the battery should be fully-charged. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Removal Seat Heater Control Module: Service and Repair Removal REMOVAL CAUTION: The Heated Seat Module mounting tab can be damaged during module removal and installation. Use care to properly align tab to prevent binding that could result in tab breakage. 1. Position the right front seat to the full rearward position. 2. Disconnect and isolate the battery negative cable. 3. Disconnect the wire harness connector (4) from the heated seat module (3). 4. Unsnap the heated seat module retaining tab (2) from the seat pan (1). 5. Remove the heated seat module (3) from the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Removal > Page 9370 Seat Heater Control Module: Service and Repair Installation INSTALLATION CAUTION: The Heated Seat Module mounting tab can be damaged during module removal and installation. Use care to properly align tab to prevent binding that could result in tab breakage. 1. Install the heated seat module (3) into the vehicle. 2. Position the retaining tab (2) with the mounting hole in the seat pan (1). Firmly apply even pressure to the module (3) until the mounting tab is fully seated. 3. Connect the wire harness connector (4) to the heated seat module (3). 4. Connect the battery negative cable. 5. Check for proper heated seat system operation. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair > Removal Sun Shade: Service and Repair Removal REMOVAL 1. Remove the drain trough. 2. Push up the front center of the sunshade (1) to pop out the front two feet. 3. Rotate the sunshade (2) so that the other feet (1) are removed from the guide track. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair > Removal > Page 9377 Sun Shade: Service and Repair Installation INSTALLATION 1. Verify the sunshade track is free of obstructions like the trim lace/ring. 2. Start with sunshade (2) at an angle with one foot (1) in the track. 3. Rotate the sunshade so the other rear foot is in the track as well as the 2 other feet (3) on the same side as the first foot. 4. To insert the remaining two feet (2) apply force to the middle front of sunshade (3) and guide them into the track. 5. Check that all the feet are in the right track and verify sunshade operation. 6. Install the drain trough. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Locations Sunroof / Moonroof Motor: Locations Component ID: 168 Component : MOTOR-SUNROOF Connector: Name : MOTOR-SUNROOF Color : LT. GRAY # of pins : 10 Pin Description Circuit 1 GROUND Z937 18BK/YL 2 SUNROOF SWITCH SUPPLY Q6 20OR/LG 3 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F996 20PK/YL 4 SUNROOF VENT SWITCH SENSE Q4 20OR/YL 5 SUNROOF OPEN SWITCH SENSE Q3 20OR/TN 6 FUSED B(+) A927 18RD/GY 7-- 8-9-10 SUNROOF CLOSE SWITCH SENSE Q5 20OR/LB Component Location - 41 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Locations > Page 9381 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Locations > Page 9382 Sunroof / Moonroof Motor: Diagrams Component ID: 168 Component : MOTOR-SUNROOF Connector: Name : MOTOR-SUNROOF Color : LT. GRAY # of pins : 10 Pin Description Circuit 1 GROUND Z937 18BK/YL 2 SUNROOF SWITCH SUPPLY Q6 20OR/LG 3 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F996 20PK/YL 4 SUNROOF VENT SWITCH SENSE Q4 20OR/YL 5 SUNROOF OPEN SWITCH SENSE Q3 20OR/TN 6 FUSED B(+) A927 18RD/GY 7-- 8-9-10 SUNROOF CLOSE SWITCH SENSE Q5 20OR/LB Component Location - 41 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Locations > Page 9383 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Removal Sunroof / Moonroof Motor: Service and Repair Removal REMOVAL 1. Drop headliner to dash. 2. Disconnect the electrical connector (1). 3. Remove three motor assembly attaching screws (4) from bottom side of motor assembly (3) and remove motor assembly from the motor bracket. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Removal > Page 9386 Sunroof / Moonroof Motor: Service and Repair Installation INSTALLATION 1. If sunroof was open when drive motor was removed, carefully move glass panel into closed position and remove glass panel. 2. Set lifter arm timing by manually sliding the mechanisms (1) in the track until timing holes in the trollies are aligned with the timing holes in the lifter arm cams (2) and insert pins (3) into the mechanisms to hold mechanisms in closed position. 3. Place motor (3) into position and install screws (4) attaching motor to bracket (2). 4. Tighten the screws (4) to 3 Nm (26 in. lbs.). 5. If sunroof glass panel was removed previously, remove the timing pins and install the sunroof glass panel. 6. Partially install the headliner and connect the sunroof wiring electrical connectors. 7. Temporarily install sunroof switch and perform the sunroof motor teach procedure. 8. Test sunroof operation, adjust glass as necessary. 9. Raise headliner to roof. Complete the headliner installation. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Description and Operation > Description Sunroof / Moonroof Switch: Description and Operation Description DESCRIPTION The power sunroof switch (2) is a combination push-button and rocker switch module mounted in the Courtesy/Reading Lamp assembly (1). The sunroof switch is a direct contact unit that is directly wired to the sunroof motor/module assembly. The sunroof switch performs the following functions: - Power sunroof open (back of switch pushed) - Power sunroof express open (back of switch pushed and released) - Power sunroof closed (front of switch pushed) - Power sunroof express closed (front of switch pushed and released) - Power sunroof vent (switch center button pushed) The power sunroof switch cannot be repaired. If the individual components are damaged or inoperative the switch assembly must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Description and Operation > Description > Page 9391 Sunroof / Moonroof Switch: Description and Operation Operation OPERATION The sunroof is electrically operated from two switches located in the headliner on the courtesy/reading lamp assembly. The power sunroof switch is hard wired to the sunroof motor/module assembly. The "VENT" switch is a push button type switch and opens the sunroof to the vent position only. The other switch "OPEN/CLOSED" is a rocker type switch for opening and closing the sunroof. Pressing and releasing the open button once, the sunroof will express open and the wind deflector will raise. If the button is pressed a second time the sunroof will stop in that position. Pressing and releasing the close button once will express close the sunroof. If the close button is pressed a second time during the express close operation the sunroof will stop in that position. The switch is grounded at one terminal and receives a 5 volt signal from the sunroof motor/module on the remaining three terminals. The switch pulls down the 5 volt reference voltage from the module signaling it to perform the desired function. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Testing and Inspection > Control Switch Sunroof / Moonroof Switch: Testing and Inspection Control Switch CONTROL SWITCH The following test will determine if the sunroof control switch is operating properly. 1. Remove the sunroof control switch from the overhead console. 2. Using an ohmmeter, test the switch terminals for proper continuity using the table below. If any of the terminals do not show proper continuity, replace the sunroof control switch. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Testing and Inspection > Control Switch > Page 9394 Sunroof / Moonroof Switch: Testing and Inspection Sunroof Switch SUNROOF SWITCH For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Remove the power sunroof switch. 2. Disconnect the power sunroof switch wire harness connector. 3. With the ignition key in the "RUN" position check for 5 volts on the "OPEN", "CLOSE" and "VENT" circuits of the sunroof switch harness connector. If OK, go to STEP 4. If not OK, inspect the wiring harness and connectors between the motor/module and switch for damage and repair as necessary. 4. With the ignition key in the "OFF" position check for continuity between the ground circuit of the sunroof switch harness connector and a known good ground. Continuity should be present. If OK, go to STEP 5. If not OK, inspect the wiring harness and connector and repair the ground circuit as necessary. 5. Using an ohmmeter, test the continuity of the power sunroof switch in each switch position. If OK, inspect the wiring harness and connectors for damage and repair as necessary. If not OK, replace the power sunroof switch. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Service and Repair > Removal Sunroof / Moonroof Switch: Service and Repair Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the courtesy/reading lamp lens (5). Insert a suitable flat bladed tool into the slot (6) in the courtesy/reading lamp assembly (2). Pivot the lens down and to the left to release the holding tab (4). 3. Using a suitable flat bladed tool, release the mounting tabs (5) from the sides of the sunroof control switch (4) and pull the switch down from the courtesy/reading lamp assembly (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Service and Repair > Removal > Page 9397 4. Disconnect the electrical connector (3) from the sunroof control switch (4). 5. Remove the switch from the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Service and Repair > Removal > Page 9398 Sunroof / Moonroof Switch: Service and Repair Installation INSTALLATION 1. Position the sunroof control switch (4) into the vehicle. 2. Connect the sunroof control switch electrical connector (3). 3. Insert the sunroof control switch (4) into the courtesy/reading lamp assembly (2). Push up on the switch until it is securely held in place by the mounting tabs (5). 4. Insert the mounting tab (4) on the lamp lens (5) into the right side of the lamp assembly and pivot the lens up until it snaps securely in place. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Service and Repair > Removal > Page 9399 5. Connect the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair > Removal Sunroof / Moonroof Windguard: Service and Repair Removal REMOVAL 1. Open the sunroof glass to the full open position. 2. Press the spring lock (1) with a small flat bladed tool and push the wind deflector (2) reward to release from the car top opening. 3. Repeat the previous step on the opposite side. 4. Rotate the wind deflector (1) up and release from the mounting hole (2) in the sunroof frame. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair > Removal > Page 9404 Sunroof / Moonroof Windguard: Service and Repair Installation INSTALLATION 1. Position the wind deflector springs (1) into the mounting holes (2) in the sunroof frame. 2. Rotate forward and down into position. 3. Slide the wind deflector and spring (1) forward under the car top lip and make sure the spring lock snaps into place (2) fully. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Drain: > 23-043-06 > Oct > 06 > Body - Water Leaking From Headliner After Rain/Carwash Sunroof / Moonroof Drain: Customer Interest Body - Water Leaking From Headliner After Rain/Carwash NUMBER: 23-043-06 GROUP: Body DATE: October 7, 2006 SUBJECT: Water Leak From Headliner OVERVIEW: This bulletin involves diagnosing the leak path at the sunroof and repairing the sunroof drain hose(s). MODELS: 2007 (MK-49) Compass 2007 (PM) Caliber NOTE: This bulletin applies to vehicles equipped with a sunroof (sales code GWG) built prior to October 6, 2006 (MDH 0908XX). SYMPTOM/CONDITION: Water leaking from headliner after a heavy rain or car wash. DIAGNOSIS: If the vehicle exhibits the Symptom/Condition perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open sunroof. 2. Pour water directly into the left front corner drain hole in Sunroof Front Crossmember NOTE: Water should drain fully and not overflow over Sunroof Housing channel inboard edge. Drain hose system should drain approximately 20 oz. of water when poured into the Sunroof Track over 20 seconds. Begin pouring slowly, if no water drains, STOP, do not pour additional water. 3. Does approximately 20 oz. of water drain out in 20 seconds? a. Yes - Proceed to Step # 7 b. No - Proceed to Step # 4. 4. Gain access to left front drain tube. Refer to 23 - Body/Sunroof/Drain Tube - Removal available in TechCONNECT. 5. Check left front drain tube for cuts, kinks or pinch points. NOTE: Be sure to check for kinks at the pass through grommet at the dash. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Drain: > 23-043-06 > Oct > 06 > Body - Water Leaking From Headliner After Rain/Carwash > Page 9413 6. Is drain hose cut? a. Yes - Replace left front drain tube. b. No - remove kink/pinch in drain tube. 7. Pour water directly into the right front corner drain hole in Sunroof Front Crossmember 8. Does approximately 20 oz. of water drain out in 20 seconds? a. Yes - Proceed to Step # 14 b. No - Proceed to Step # 9. 9. Gain access to right front drain tube. Refer to 23 - Body/Sunroof/Drain Tube - Removal available in TechCONNECT. 10. Check right front drain tube to see if it is wrapped around the rear washer fluid supply hose. 11. Is drain tube wrapped around the washer fluid supply hose? a. Yes - Unwrap hoses and retest. b. No - Proceed to Step # 12 12. Check right front drain tube for cuts, kinks or pinch points. NOTE: Be sure to check for kinks at the pass through grommet at the dash. 13. Is drain tube cut? a. Yes - Replace right front drain tube. b. remove kink/pinch in drain tube. 14. Pour water directly into the left rear drain hole in Sunroof Front Crossmember 15. Does approximately 20 oz. of water drain out in 20 seconds? a. Yes - Proceed to Step # 19 b. No - Proceed to Step # 16 16. Gain access to left rear drain tube. Refer to 23 - Body/Sunroof/Drain Tube - Removal available in TechCONNECT. 17. Check left rear drain tube for cuts, kinks or pinch points. 18. Is drain tube cut? a. Yes - Replace left rear drain tube. b. remove kink/pinch in drain tube. 19. Pour water directly into the right rear drain hole in Sunroof Front Crossmember 20. Does approximately 20 oz. of water drain out in 20 seconds? a. Yes - Further Diagnosis required b. No - Proceed to Step # 21 21. Gain access to right rear drain tube. Refer to 23 - Body/Sunroof/Drain Tube - Removal available in TechCONNECT. 22. Check right rear drain tube for cuts, kinks or pinch points. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Drain: > 23-043-06 > Oct > 06 > Body - Water Leaking From Headliner After Rain/Carwash > Page 9414 23. Is drain tube cut? a. Yes - Replace right rear drain tube. b. remove kink/pinch in drain tube. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Drain: > 23-043-06 > Oct > 06 > Body - Water Leaking From Headliner After Rain/Carwash Sunroof / Moonroof Drain: All Technical Service Bulletins Body - Water Leaking From Headliner After Rain/Carwash NUMBER: 23-043-06 GROUP: Body DATE: October 7, 2006 SUBJECT: Water Leak From Headliner OVERVIEW: This bulletin involves diagnosing the leak path at the sunroof and repairing the sunroof drain hose(s). MODELS: 2007 (MK-49) Compass 2007 (PM) Caliber NOTE: This bulletin applies to vehicles equipped with a sunroof (sales code GWG) built prior to October 6, 2006 (MDH 0908XX). SYMPTOM/CONDITION: Water leaking from headliner after a heavy rain or car wash. DIAGNOSIS: If the vehicle exhibits the Symptom/Condition perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open sunroof. 2. Pour water directly into the left front corner drain hole in Sunroof Front Crossmember NOTE: Water should drain fully and not overflow over Sunroof Housing channel inboard edge. Drain hose system should drain approximately 20 oz. of water when poured into the Sunroof Track over 20 seconds. Begin pouring slowly, if no water drains, STOP, do not pour additional water. 3. Does approximately 20 oz. of water drain out in 20 seconds? a. Yes - Proceed to Step # 7 b. No - Proceed to Step # 4. 4. Gain access to left front drain tube. Refer to 23 - Body/Sunroof/Drain Tube - Removal available in TechCONNECT. 5. Check left front drain tube for cuts, kinks or pinch points. NOTE: Be sure to check for kinks at the pass through grommet at the dash. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Drain: > 23-043-06 > Oct > 06 > Body - Water Leaking From Headliner After Rain/Carwash > Page 9420 6. Is drain hose cut? a. Yes - Replace left front drain tube. b. No - remove kink/pinch in drain tube. 7. Pour water directly into the right front corner drain hole in Sunroof Front Crossmember 8. Does approximately 20 oz. of water drain out in 20 seconds? a. Yes - Proceed to Step # 14 b. No - Proceed to Step # 9. 9. Gain access to right front drain tube. Refer to 23 - Body/Sunroof/Drain Tube - Removal available in TechCONNECT. 10. Check right front drain tube to see if it is wrapped around the rear washer fluid supply hose. 11. Is drain tube wrapped around the washer fluid supply hose? a. Yes - Unwrap hoses and retest. b. No - Proceed to Step # 12 12. Check right front drain tube for cuts, kinks or pinch points. NOTE: Be sure to check for kinks at the pass through grommet at the dash. 13. Is drain tube cut? a. Yes - Replace right front drain tube. b. remove kink/pinch in drain tube. 14. Pour water directly into the left rear drain hole in Sunroof Front Crossmember 15. Does approximately 20 oz. of water drain out in 20 seconds? a. Yes - Proceed to Step # 19 b. No - Proceed to Step # 16 16. Gain access to left rear drain tube. Refer to 23 - Body/Sunroof/Drain Tube - Removal available in TechCONNECT. 17. Check left rear drain tube for cuts, kinks or pinch points. 18. Is drain tube cut? a. Yes - Replace left rear drain tube. b. remove kink/pinch in drain tube. 19. Pour water directly into the right rear drain hole in Sunroof Front Crossmember 20. Does approximately 20 oz. of water drain out in 20 seconds? a. Yes - Further Diagnosis required b. No - Proceed to Step # 21 21. Gain access to right rear drain tube. Refer to 23 - Body/Sunroof/Drain Tube - Removal available in TechCONNECT. 22. Check right rear drain tube for cuts, kinks or pinch points. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Drain: > 23-043-06 > Oct > 06 > Body - Water Leaking From Headliner After Rain/Carwash > Page 9421 23. Is drain tube cut? a. Yes - Replace right rear drain tube. b. remove kink/pinch in drain tube. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Drain Hose Sunroof / Moonroof Drain: Service and Repair Drain Hose Removal REMOVAL 1. Drop down the headliner as necessary to gain access to the drain hoses. 2. Disconnect the front hoses (2) from the sunroof assembly (1). 3. Release the support clips (3) and disconnect the lower grommet and remove the hose. 4. Disconnect the rear hoses (2) from the sunroof assembly (1) and release the support clips (3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Drain Hose > Page 9424 5. Separate the remaining support clips (1). 6. Disconnect the grommet (2) from the body (3) and remove the rear hoses as necessary. Installation INSTALLATION 1. Install the rear hoses (4) and connect the grommets (2) to the body (3). 2. Connect the support clips (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Drain Hose > Page 9425 3. Route the hose as required and connect the remaining support clips (3). 4. Connect the hoses (2) to the sunroof assembly (1). 5. Connect the front hose lower grommet to the body. 6. Connect the front hose (2) to the sunroof assembly (1) and connect the support clips (3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Drain Hose > Page 9426 Sunroof / Moonroof Drain: Service and Repair Trough Removal REMOVAL 1. Remove the glass. 2. Separate the trough pins (3) from the glass lift mechanisms (1). 3. Slide trough (1) to one side and push down on the center of the trough until the guide shoe tab (3) releases from the track (2). 4. Slide the trough in the opposite direction to release the other shoe and lift the trough out of the sunroof opening. Installation INSTALLATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Drain Hose > Page 9427 1. Insert one of the trough guides (3) and guide shoe (2) into the track. 2. Push down on the center of the trough (1) to flatten it out and install the remaining trough guide (3) and guide shoe (2) into the track. 3. Install the trough guide pins into the glass lift mechanism (3) and seat fully. 4. Install the glass. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair > Removal Sunroof / Moonroof Frame: Service and Repair Removal REMOVAL 1. Move glass panel to fully closed position. 2. Disconnect and isolate negative battery cable (4). 3. Remove control switch. 4. Drop headliner to seat. 5. Disconnect the electrical connector. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair > Removal > Page 9432 6. Disconnect drain tubes (2) from sunroof housing (1). 7. Remove two module side bracket (4) bolts (6) and loosen the six remaining fasteners (3). 8. Remove the six (3) fasteners attaching sunroof module assembly (1) to roof panel. 9. Remove the glass panel. 10. Remove the sunshade. 11. Remove the drive motor. 12. Remove the wire harness. 13. Remove the trough guides. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair > Removal > Page 9433 Sunroof / Moonroof Frame: Service and Repair Installation INSTALLATION NOTE: Mk Sunroof assembly shown, JS similar. 1. Install the trough guides. 2. Install the drive motor. 3. Install the sunshade. 4. Install the glass panel. 5. Raise rear end of sunroof module assembly (1) and guide into position and start the six fasteners (3). 6. Visually line up the alignment guide holes (2) with the guide holes in the roof of the vehicle. 7. Tighten the six fasteners (3) to 9 Nm (80 in. lbs.). 8. Tighten the two side bracket fasteners (6) to 9 Nm (80 in. lbs.). 9. Connect the drain tubes (2) to the assembly (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair > Removal > Page 9434 10. Connect the electrical connector. 11. Connect battery negative cable (4). 12. Test sunroof operation, adjust glass as necessary. 13. Partially install the headliner and connect the sunroof wiring electrical connectors. 14. Temporarily install sunroof switch and perform the sunroof motor teach procedure. 15. Raise headliner installation. 16. Verify correct sunroof operation. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Adjustments Sunroof / Moonroof Panel: Adjustments SUNROOF GLASS PANEL ADJUSTMENT 1. Move the sunshade rearward to the open position. 2. Move the sunroof glass panel to the fully closed position. 3. Adjust the glass one corner at a time. a. Loosen four glass screws (1). b. Lift glass assembly and align the top of the glass panel to the top of the roof panel. c. Tighten screw to 3 Nm (26 in. lbs.). d. Repeat steps a. and b. for each corner of the glass panel. e. When properly adjusted, the front of the glass panel is 1.0 mm (0.04 in.) to 2.0 mm (0.08 in.) lower than the roof surface and the rear edge of the glass panel is 1.0 mm (0.04 in.) to 2.0 mm (0.08 in.) higher than the roof surface. NOTE: When properly adjusted, the front of the glass panel (3) is 1.0 mm (0.04 in.) to 2.0 mm (0.08 in.) lower than the roof surface (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Adjustments > Page 9438 NOTE: When properly adjusted, the rear edge of the glass panel (3) is 1.0 mm (0.04 in.) to 2.0 mm (0.08 in.) higher than the roof surface (2). 4. Verify sunroof operation and alignment. Check fit and re-adjust as necessary. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Removal Sunroof / Moonroof Panel: Service and Repair Removal REMOVAL 1. Slide sunshade rearward to the open position. 2. Move the glass panel to the closed position. 3. Remove the four glass panel screws (1). 4. Lift off glass panel and remove from vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Removal > Page 9441 Sunroof / Moonroof Panel: Service and Repair Installation INSTALLATION 1. Position glass panel (2) on to mechanism lift arm. 2. Start the four attaching screws (1). 3. Center glass in opening by running a business card around the glass. 4. Adjust glass panel. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Service and Repair > Removal Sunroof / Moonroof Weatherstrip: Service and Repair Removal REMOVAL 1. Remove sunroof glass panel. 2. Place glass panel on clean work area with the top side up. Support the glass assembly from underside to avoid bending or otherwise damaging the mounting tabs. 3. Grasp the seal (1) and pull seal away from the glass panel (2). The seal is a one piece seal. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Service and Repair > Removal > Page 9446 Sunroof / Moonroof Weatherstrip: Service and Repair Installation INSTALLATION NOTE: Always position seal seam on center of the passenger side of glass panel. 1. Place seal (1) into position. 2. Seat the seal into the glass channel fully. Using care working the seal around the glass (2), being careful not to over stretch the seal while installing. 3. Install the glass panel. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Bottom > Seat Bottom Frame > Component Information > Technical Service Bulletins > Customer Interest for Seat Bottom Frame: > 23-028-06A > Sep > 06 > Interior - Front Seat Cushion Loose/Clicks/Creaks Seat Bottom Frame: Customer Interest Interior - Front Seat Cushion Loose/Clicks/Creaks NUMBER: 23-028-06 REV. A GROUP: Body DATE: September 20, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-028-06, DATED JULY 19, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES AN UPDATED OVERVIEW, VEHICLE BUILD DATE AND REPAIR PROCEDURE. SUBJECT: Clicking/Creaking Sound From Seat Or Looseness At Front Of Seat Cushion OVERVIEW: This bulletin involves adding electrical tape to the cushion pan attachment crosstube, installing new plastic brackets on the driver, passenger or both front seat(s) **and removing the pink foam block from both the lower front outboard side shields**. MODELS: 2007 (PM) Caliber 2007 (MK-49) Compass NOTE: **This bulletin applies to vehicles built before September 16, 2006 (MDH 0916XX).** SYMPTOM/CONDITION: The front cushion of the seat may feel loose and/or the seats may make a clicking or creaking sound when: i. Stopping and accelerating ii. Driving around corners DIAGNOSIS: If the sound is present for the driver or passenger front seats as described in the Symptom/Condition perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Bottom > Seat Bottom Frame > Component Information > Technical Service Bulletins > Customer Interest for Seat Bottom Frame: > 23-028-06A > Sep > 06 > Interior - Front Seat Cushion Loose/Clicks/Creaks > Page 9457 2. Move the seat to the forward position. 3. From under the seat remove the bolts (2) and the straps (1). 4. Disconnect the electrical connector, if equipped. 5. Is tape already present on the crosstube? a. Yes - Proceed to Step # 7. b. No - Proceed to Step # 6. 6. Apply electrical tape per (Fig. 2). Wrap the tape around the crosstube, two wraps. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Bottom > Seat Bottom Frame > Component Information > Technical Service Bulletins > Customer Interest for Seat Bottom Frame: > 23-028-06A > Sep > 06 > Interior - Front Seat Cushion Loose/Clicks/Creaks > Page 9458 7. Install new plastic brackets. NOTE: Each front seat has two brackets. 8. Reinstall metal straps and bolts, torque to 12.5Nm (110 in. lbs.) 9. **Is the vehicle a Compass built before September 16, 2006?** a. Yes - Proceed to Step # 10. b. No - Repair Complete. CAUTION: Do not pull side shield out too much in the next step. Only pull out enough to access the pink foam block. 10. **Using your hand pull the lower outboard side shield away from the seat frame (Fig. 3).** 11. **Remove the pink foam block from the lower outboard side shield.** 12. **Ensure the lower outboard side shield is snapped back into place.** NOTE: Be sure to perform this action for both front seats. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Bottom > Seat Bottom Frame > Component Information > Technical Service Bulletins > Customer Interest for Seat Bottom Frame: > 23-028-06A > Sep > 06 > Interior - Front Seat Cushion Loose/Clicks/Creaks > Page 9459 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Bottom > Seat Bottom Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Bottom Frame: > 23-028-06A > Sep > 06 > Interior Front Seat Cushion Loose/Clicks/Creaks Seat Bottom Frame: All Technical Service Bulletins Interior - Front Seat Cushion Loose/Clicks/Creaks NUMBER: 23-028-06 REV. A GROUP: Body DATE: September 20, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-028-06, DATED JULY 19, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES AN UPDATED OVERVIEW, VEHICLE BUILD DATE AND REPAIR PROCEDURE. SUBJECT: Clicking/Creaking Sound From Seat Or Looseness At Front Of Seat Cushion OVERVIEW: This bulletin involves adding electrical tape to the cushion pan attachment crosstube, installing new plastic brackets on the driver, passenger or both front seat(s) **and removing the pink foam block from both the lower front outboard side shields**. MODELS: 2007 (PM) Caliber 2007 (MK-49) Compass NOTE: **This bulletin applies to vehicles built before September 16, 2006 (MDH 0916XX).** SYMPTOM/CONDITION: The front cushion of the seat may feel loose and/or the seats may make a clicking or creaking sound when: i. Stopping and accelerating ii. Driving around corners DIAGNOSIS: If the sound is present for the driver or passenger front seats as described in the Symptom/Condition perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Bottom > Seat Bottom Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Bottom Frame: > 23-028-06A > Sep > 06 > Interior Front Seat Cushion Loose/Clicks/Creaks > Page 9465 2. Move the seat to the forward position. 3. From under the seat remove the bolts (2) and the straps (1). 4. Disconnect the electrical connector, if equipped. 5. Is tape already present on the crosstube? a. Yes - Proceed to Step # 7. b. No - Proceed to Step # 6. 6. Apply electrical tape per (Fig. 2). Wrap the tape around the crosstube, two wraps. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Bottom > Seat Bottom Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Bottom Frame: > 23-028-06A > Sep > 06 > Interior Front Seat Cushion Loose/Clicks/Creaks > Page 9466 7. Install new plastic brackets. NOTE: Each front seat has two brackets. 8. Reinstall metal straps and bolts, torque to 12.5Nm (110 in. lbs.) 9. **Is the vehicle a Compass built before September 16, 2006?** a. Yes - Proceed to Step # 10. b. No - Repair Complete. CAUTION: Do not pull side shield out too much in the next step. Only pull out enough to access the pink foam block. 10. **Using your hand pull the lower outboard side shield away from the seat frame (Fig. 3).** 11. **Remove the pink foam block from the lower outboard side shield.** 12. **Ensure the lower outboard side shield is snapped back into place.** NOTE: Be sure to perform this action for both front seats. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Bottom > Seat Bottom Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Bottom Frame: > 23-028-06A > Sep > 06 > Interior Front Seat Cushion Loose/Clicks/Creaks > Page 9467 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Fabric Cleaning/Care Seat Cover: Technical Service Bulletins Interior - Fabric Cleaning/Care NUMBER: 23-021-06 REV. A GROUP: Body DATE: August 9, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-021-06, DATED MAY 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITIONAL MODELS AND AN ADDITIONAL PART NUMBER. SUBJECT: YES Essentials(R) Stain, Odor, & Static Resistant Fabric Care MODELS: 2007 (CS) Pacifica 2007 (DR) Ram Truck **2007 (HB/HG) **2007 (JK) **2007 (JS) Avenger/Sebring ** **2007 (KA) Nitro** 2007 (MK) Compass **2007 (ND) Dakota** 2007 (PM) Caliber **2007 (PT) PT Cruiser** NOTE: This bulletin applies to vehicles equipped with YES Essentials(R) stain, odor, & static resistant fabric (sales code XGW). PARTS REQUIRED: The premium cloth upholstery in the vehicles listed is the new YES Essentials(R) stain, odor, & static resistant fabric. YES Essentials(R) fabric is an easy-care material that repels and releases soil to maintain the like-new appearance. Spills remain on the surface of the fabric to allow for easy clean up and to prevent stains and odors. The material is antimicrobial and static resistant. YES Essentials(R) fabric may be cleaned in the following manner: ^ Do NOT use any solvents or fabric protectants on Yes Essentials(R) fabric. ^ Remove as much of the stain as possible by blotting with a clean, dry towel. ^ Blot any remaining stain with a clean, damp towel. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Fabric Cleaning/Care > Page 9472 ^ For tough stains, apply Mopar(R) Total Clean, p/n 04897840AA, or a mild soap solution to a clean damp cloth and remove the stain. Use a fresh, damp towel to remove the soap residue. ^ For grease stains, apply Mopar(R) Multi-purpose Cleaner, p/n 05127532AA, to a clean, damp cloth and remove the stain. Use a fresh, damp towel to remove the soap residue. CAUTION: YES Essentials(R) stain, odor, & static resistant fabric is NOT compatible with aftermarket fabric-protecting coatings. Any additional protection will damage the performance of the YES Essentials(R) stain, odor, & static resistant fabric. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Locations > Heater-Seat Cushion-Left Seat Heater: Locations Heater-Seat Cushion-Left Component ID: 106 Component : HEATER-SEAT CUSHION-LEFT Connector: Name : HEATER-SEAT CUSHION-LEFT Color : GREEN # of pins : 2 Gender : FEMALE Pin Description Circuit 1 LEFT SEAT HEATER B(+) DRIVER P187 16LG/BR Pin Description Circuit 1 LEFT SEAT HEATER B(+) DRIVER P187 18LG/VT 2 GROUND Z960 18BK Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Locations > Heater-Seat Cushion-Left > Page 9477 Connector: Name : HEATER-SEAT CUSHION-LEFT Color : GREEN # of pins : 2 Qualifier : (COMPONENT SIDE) Pin Description Circuit 1 LEFT SEAT HEATER B(+) DRIVER P187 18BK 2 GROUND Z960 18BK Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Locations > Heater-Seat Cushion-Left > Page 9478 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Locations > Heater-Seat Cushion-Left > Page 9479 Seat Heater: Locations Heater-Seat Cushion-Right Component ID: 107 Component : HEATER-SEAT CUSHION-RIGHT Connector: Name : HEATER-SEAT CUSHION-RIGHT Color : GREEN # of pins : 2 Gender : FEMALE Pin Description Circuit 1 RIGHT SEAT HEATER B(+) DRIVER P188 18LG/VT Pin Description Circuit 1 RIGHT SEAT HEATER B(+) DRIVER P188 16LG/BR 2 GROUND Z940 18BK Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Locations > Heater-Seat Cushion-Left > Page 9480 Connector: Name : HEATER-SEAT CUSHION-RIGHT Color : GREEN # of pins : 2 Qualifier : (COMPONENT SIDE) Pin Description Circuit 1 RIGHT SEAT HEATER B(+) DRIVER P188 18BK 2 GROUND Z940 18BK Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Locations > Heater-Seat Cushion-Left > Page 9481 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Heater-Seat Back-Left Seat Heater: Diagrams Heater-Seat Back-Left Component ID: 104 Component : HEATER-SEAT BACK-LEFT Connector: Name : HEATER-SEAT BACK-LEFT Color : BLACK # of pins : 2 Pin Description Circuit 1 LEFT SEAT HEATER B(+) DRIVER P187 18BK 2 GROUND Z960 18BK Connector: Name : HEATER-SEAT BACK-LEFT Color : BLACK # of pins : 2 Qualifier : (COMPONENT SIDE) Pin Description Circuit 1 LEFT SEAT HEATER B(+) DRIVER P187 18YL 2 GROUND Z960 18YL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Heater-Seat Back-Left > Page 9484 Seat Heater: Diagrams Heater-Seat Back-Right Component ID: 105 Component : HEATER-SEAT BACK-RIGHT Connector: Name : HEATER-SEAT BACK-RIGHT Color : BLACK # of pins : 2 Pin Description Circuit 1 RIGHT SEAT HEATER B(+) DRIVER P188 18BK 2 GROUND Z940 18BK Connector: Name : HEATER-SEAT BACK-RIGHT Color : BLACK # of pins : 2 Qualifier : (COMPONENT SIDE) Pin Description Circuit 1 RIGHT SEAT HEATER B(+) DRIVER P188 18YL 2 GROUND Z940 18YL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Heater-Seat Back-Left > Page 9485 Seat Heater: Diagrams Heater-Seat Cushion-Left Component ID: 106 Component : HEATER-SEAT CUSHION-LEFT Connector: Name : HEATER-SEAT CUSHION-LEFT Color : GREEN # of pins : 2 Gender : FEMALE Pin Description Circuit 1 LEFT SEAT HEATER B(+) DRIVER P187 16LG/BR Pin Description Circuit 1 LEFT SEAT HEATER B(+) DRIVER P187 18LG/VT 2 GROUND Z960 18BK Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Heater-Seat Back-Left > Page 9486 Connector: Name : HEATER-SEAT CUSHION-LEFT Color : GREEN # of pins : 2 Qualifier : (COMPONENT SIDE) Pin Description Circuit 1 LEFT SEAT HEATER B(+) DRIVER P187 18BK 2 GROUND Z960 18BK Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Heater-Seat Back-Left > Page 9487 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Heater-Seat Back-Left > Page 9488 Seat Heater: Diagrams Heater-Seat Cushion-Right Component ID: 107 Component : HEATER-SEAT CUSHION-RIGHT Connector: Name : HEATER-SEAT CUSHION-RIGHT Color : GREEN # of pins : 2 Gender : FEMALE Pin Description Circuit 1 RIGHT SEAT HEATER B(+) DRIVER P188 18LG/VT Pin Description Circuit 1 RIGHT SEAT HEATER B(+) DRIVER P188 16LG/BR 2 GROUND Z940 18BK Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Heater-Seat Back-Left > Page 9489 Connector: Name : HEATER-SEAT CUSHION-RIGHT Color : GREEN # of pins : 2 Qualifier : (COMPONENT SIDE) Pin Description Circuit 1 RIGHT SEAT HEATER B(+) DRIVER P188 18BK 2 GROUND Z940 18BK Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Heater-Seat Back-Left > Page 9490 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Description and Operation > Cushion Pad Heater Seat Heater: Description and Operation Cushion Pad Heater Description DESCRIPTION Vehicles equipped with the optional heated seat system have two, carbon fiber heated seat elements, located in each front seat. One heating element is used for each seat cushion and another for each seat back. Each of the heated seat element consists of multiple heating circuits operating in parallel throughout the carbon fiber element. The heated seat elements are captured between the leather or cloth trim cover and the seat cushion assembly. If a malfunction occurs in one or more of the individual carbon fiber circuits, the others will continue to provide heat. The heated seat elements cannot be repaired. If found to be damaged or inoperative, a new heating element assembly must be installed. Operation OPERATION One end of the heated seat element is connected to ground at all times through a splice under the seat. Battery current is directed to the other end of the heated seat element by the heated seat module. The heated seat module will energize the heated seat element when the heated seat switch is depressed in the LOW or HIGH position. As electrical current passes through the heated seat element, the resistance of the wire used in the element disperses some of the electrical current in the form of heat. The heat produced by the heated seat element then radiates through the underside of the seat cushion and seat back trim covers, warming the seat cover and its occupant. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Description and Operation > Cushion Pad Heater > Page 9493 Seat Heater: Description and Operation Heated Seats Description DESCRIPTION WARNING: The front passenger seat assembly contains critical components that affect the front passenger airbag deployment. Correctly functioning front passenger seat components are critical for the Occupant Classification System (OCS) to properly classify the front passenger and calculate the proper airbag deployment. Unapproved modifications or service procedures to the front passenger seat assembly, its related components, or trim cover may inadvertently change the airbag deployment in case of a frontal crash. This could result in death or serious injury to the front seat passenger if the vehicle is involved in an accident. The following requirements must be strictly adhered to: - Do not modify the front passenger seat assembly or components in any way. - Do not modify the front seat center console or center position seat in any way. - Do not use prior or future model year seat trim covers not designated for the specific model being repaired. Always use the correct seat trim cover specified for the vehicle. - Do not replace the seat trim cover with an aftermarket trim cover. - Do not add a secondary trim cover other than those approved by DaimlerChrysler/Mopar(R). - At no time should any Supplemental Restraint System (SRS) component or SRS related component or fastener be modified or replaced with any part except those which are approved by DaimlerChrysler/Mopar(R). Vehicles with the heated seat option can be visually identified by the two heated seat switches located in the center stack (1) of the instrument panel. The switches are located on the outer edges of the accessory switch bank (2). The heated seat system allows the driver and front seat passenger to select from two different levels of electrical seat heating (HI/LO). The heated seat system for this vehicle includes the following major components: - Heated Seat Elements - Four heated seat elements are used per vehicle. Two heated seat elements are integral to each seat, one in the seat back and the other in the seat cushion. - Heated Seat Module - One heated seat module is used per vehicle. The Heated Seat Module is mounted under the left front seat. This module contains the control logic and software for the front heated seat system. The module communicates on the Local Interface Network (LIN) data bus. - Heated Seat Switches - Two heated seat switches are used per vehicle, one for each heated seat. Both switches are mounted in the instrument panel center stack. - Instrument Cluster (CCN) - A Cab Compartment Node (CCN) is part of the instrument cluster on this vehicle. The CCN utilizes integrated software and information carried on the LIN data bus. The CCN serves as the link between the heated seat switches and the heated seat module. Operation OPERATION The heated seat system operates on battery current received through a fuse in the Totally Integrated Power Module (TIPM). Fused ignition switch output (Run) circuits are used, so that the heated seat system will only operate when the ignition switch is in the ON position. The heated seat system will turn Off automatically whenever the ignition switch is turned to any position except ON. A Heated Seat Module is used to control the heated seat system. The module responds to heated seat switch messages and ignition switch status inputs by controlling the 12v output to the front seat heating elements through integral solid-state relays. When either of the heated seat switches are depressed a switch status message is sent to the Cab Compartment Node (CCN) or instrument cluster via the Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Description and Operation > Cushion Pad Heater > Page 9494 Local Interface Network (LIN) data bus. The CCN then sends a message via the LIN data bus to the heated seat module, signaling the module to energize the heating element for the selected seat. Amber Light Emitting Diodes (LEDs) in the top portion of each switch indicate the level of heat in use: Two LEDs are illuminated for high, one for low, and none for off. The heated seat module sends the LED illumination message to the CCN via the LIN data bus. The CCN then sends the LED illumination message to the accessory switch bank so that the appropriate LEDs are illuminated for any given heating level. Pressing the switch once will select high-level heating. Pressing the switch a second time will select low-level heating. Pressing the switch a third time will shut the heating elements off. The heated seat module energizes an integral solid-state relay, which supplies battery current to the heating elements. When high-temperature heating is selected, the heaters provide a boosted heat level during the first four minutes of operation after heating is activated once per ignition cycle. The heat output then drops to the normal high-temperature level. If high-level heating is selected, the control system will automatically switch to the low level after thirty minutes (twenty six minutes on first activation of an ignition cycle) of continuous operation. At that time, the number of illuminated LEDs changes from two to one, indicating the change. Operation on the low setting also turns off automatically after thirty minutes. The module will automatically turn off the heating elements if it detects an OPEN or LOW short in the heating element circuit. In the event an OPEN or LOW short in the heating element circuit is detected when the heated seats are first initialized, the two LEDs will light for two seconds and go out as an indicator of a system problem. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Heated Seat System Seat Heater: Testing and Inspection Heated Seat System HEATED SEAT SYSTEM In order to obtain conclusive testing, the heated seat system and the Local Interface Network (LIN) data bus circuit must be checked. Any diagnosis of the heated seat system should begin with, the use of a scan tool and the appropriate diagnostic information. Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. NOTE: Vehicles equipped with the heated seat option utilize a low voltage cut-off feature. This feature turns off power to the heated seat system anytime vehicle voltage is below 11.7v or above 15.5v. Be certain to check the vehicle electrical system for proper voltage anytime the power seat system appears inoperative. Before any testing of the heated seat system is attempted, the battery should be fully-charged. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Heated Seat System > Page 9497 Seat Heater: Testing and Inspection Heated Seat Element HEATED SEAT ELEMENT Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. The wire harness connectors (2 & 3) for the heating elements are located under the seat (1). NOTE: When checking heated seat elements for continuity, be certain to move the heating element being checked. Moving the element, such as sitting in the seat will eliminate the possibility of an intermittent open in the element which would only be evident if the element was in a certain position. Failure to check the element in various positions could result in an incomplete test. 1. Locate and disconnect the seat electrical connector. 2. Check the resistance between the circuit leading in and out of the suspect heated seat element. The resistance should be between 3.0 - 5.5 ohms for a seat cushion element and 4.0 - 6.0 ohms for a seat back element. If OK, refer to Heated Seats testing. If not OK, replace the inoperative heated seat element. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Removal Seat Heater: Service and Repair Removal REMOVAL NOTE: Do not remove the factory installed heating elements (3) from the seat or seat back cushions. The original element is permanently attached and cannot be removed without permanent damage. The replacement heating element is designed to be applied directly on top of the inoperative factory installed heating element. 1. Disconnect and isolate the battery negative cable. 2. Remove the appropriate seat cushion or seat back trim cover. 3. Disconnect the inoperative heated seat cushion or seat back element electrical connectors (2). 4. Locate the wires leading from the inoperative heating element and cut them off flush with the edge of the original heating element. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Removal > Page 9500 Seat Heater: Service and Repair Installation INSTALLATION 1. Peel off the adhesive backing on the back of the replacement heating element (2) and stick directly on top of the factory installed heating element (1). CAUTION: During the installation of the replacement heating element, be careful not to fold or crease the element assembly. Folds or creases will cause premature failure. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Removal > Page 9501 2. Connect the new heating element electrical connectors (3 & 4). 3. Connect the battery negative cable. 4. Verify heated seat system operation. 5. Install the appropriate seat cushion or seat back trim cover. NOTE: Make certain the seat wire harness is correctly routed through the seat and seat back. The excess wire between the cushion and back elements should be securely tucked between the rear of the cushion foam and the rear carpet flap of the trim cover. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Locations Seat Heater Control Module: Locations Component ID: 155 Component : MODULE-HEATED SEATS Connector: Name : MODULE-HEATED SEATS Color : BLACK # of pins : 10 A-B-C-D LEFT SEAT HEATER B(+) DRIVER P187 16LG/BR D RIGHT SEAT HEATER B(+) DRIVER P188 16LG/BR E FUSED IGNITION SWITCH OUTPUT (RUN) F937 14PK/YL F GROUND Z960 18BK G-- H-J LIN BUS D506 20WT/DG K RIGHT SEAT HEATER B(+) DRIVER P188 16LG/VT K LEFT SEAT HEATER B(+) DRIVER P187 16LG/VT Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Locations > Page 9505 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Locations > Page 9506 Seat Heater Control Module: Diagrams Component ID: 155 Component : MODULE-HEATED SEATS Connector: Name : MODULE-HEATED SEATS Color : BLACK # of pins : 10 A-B-C-D LEFT SEAT HEATER B(+) DRIVER P187 16LG/BR D RIGHT SEAT HEATER B(+) DRIVER P188 16LG/BR E FUSED IGNITION SWITCH OUTPUT (RUN) F937 14PK/YL F GROUND Z960 18BK G-- H-J LIN BUS D506 20WT/DG K RIGHT SEAT HEATER B(+) DRIVER P188 16LG/VT K LEFT SEAT HEATER B(+) DRIVER P187 16LG/VT Component Location - 57 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Locations > Page 9507 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Description and Operation > Description Seat Heater Control Module: Description and Operation Description DESCRIPTION The heated seat module (2) is located under the left front seat. It has a single electrical connector (1) and a push pin style retainer that secures it to the seat pan. The module can be accessed from under the front left seat with the seat in the full back position. The heated seat module is a microprocessor designed to use the Local Interface Network (LIN) data bus messages from the instrument cluster also known as the Cabin Compartment Node (CCN). The CCN receives inputs from the heated seat switches and in turn signals the heated seat module to operate the heated seat elements for both front seats. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Description and Operation > Description > Page 9510 Seat Heater Control Module: Description and Operation Operation OPERATION The heated seat module operates on fused battery current received from the ignition switch. The module is grounded to the body at all times through the electrical connector. Inputs to the module include Local Interface Network (LIN) data bus messages and standard hardwired 12 volt power and ground. In response to the LIN inputs the heated seat module will control the battery current to the appropriate heated seat elements. When a heated seat switch LIN data bus signal is received by the heated seat module, the module energizes the selected heated seat element. The Low heat set point is about 38° C (100.4° F), and the High heat set point is about 42° C (107.6° F). In addition to operating the heated seat elements, the heated seat module sends LED illumination messages to the CCN via the LIN data bus. The CCN then sends the LED illumination message to the accessory switch bank so that the appropriate LEDs are illuminated for any given heating level. Pressing the switch once will select high-level heating. Pressing the switch a second time will select low-level heating. Pressing the switch a third time will shut the heating elements off. If the heated seat module detects a heated seat element OPEN or SHORT circuit, it will record and store the appropriate diagnostic trouble code (DTC). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Description and Operation > Page 9511 Seat Heater Control Module: Testing and Inspection HEATED SEAT MODULE In order to obtain conclusive testing, the heated seat system and the Local Interface Network (LIN) data bus circuit must be checked. Any diagnosis of the heated seat system should begin with the use of a scan tool. Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. NOTE: Vehicles equipped with the heated seat option utilize a low voltage cut-off feature. This feature turns off power to the heated seat system anytime vehicle voltage is below 11.7v or above 15.5v. Be certain to check the vehicle electrical system for proper voltage anytime the power seat system appears inoperative. Before any testing of the heated seat system is attempted, the battery should be fully-charged. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Service and Repair > Removal Seat Heater Control Module: Service and Repair Removal REMOVAL CAUTION: The Heated Seat Module mounting tab can be damaged during module removal and installation. Use care to properly align tab to prevent binding that could result in tab breakage. 1. Position the right front seat to the full rearward position. 2. Disconnect and isolate the battery negative cable. 3. Disconnect the wire harness connector (4) from the heated seat module (3). 4. Unsnap the heated seat module retaining tab (2) from the seat pan (1). 5. Remove the heated seat module (3) from the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Service and Repair > Removal > Page 9514 Seat Heater Control Module: Service and Repair Installation INSTALLATION CAUTION: The Heated Seat Module mounting tab can be damaged during module removal and installation. Use care to properly align tab to prevent binding that could result in tab breakage. 1. Install the heated seat module (3) into the vehicle. 2. Position the retaining tab (2) with the mounting hole in the seat pan (1). Firmly apply even pressure to the module (3) until the mounting tab is fully seated. 3. Connect the wire harness connector (4) to the heated seat module (3). 4. Connect the battery negative cable. 5. Check for proper heated seat system operation. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Description and Operation > Description Seat Heater Switch: Description and Operation Description DESCRIPTION The heated seat switches are located in the center stack (1) of the instrument panel. The switches are located on the outer edges of the accessory switch bank (2). If either of the switches is damaged or inoperative the complete accessory switch bank assembly must be replaced. When either of the heated seat switches are depressed a switch status message is sent to the Cab Compartment Node (CCN) or instrument cluster via the Local Interface Network (LIN) data bus. The CCN then sends a message via the LIN data bus to the heated seat module, signaling the module to energize the heating element for the selected seat. Amber Light Emitting Diodes (LEDs) in the top portion of each switch indicate the level of heat in use: Two LEDs are illuminated for high, one for low, and none for off. The heated seat module sends the LED illumination message to the CCN via the LIN data bus. The CCN then sends the LED illumination message to the accessory switch bank so that the appropriate LEDs are illuminated for any given heating level. Pressing the switch once will select high-level heating. Pressing the switch a second time will select low-level heating. Pressing the switch a third time will shut the heating elements off. The LED indicator lamps in each heated seat switch cannot be repaired. If the LED lamps are inoperative or damaged, or the switch is inoperative or damaged the complete accessory switch bank assembly must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Description and Operation > Description > Page 9519 Seat Heater Switch: Description and Operation Operation OPERATION The heated seat switches are active any time the Local Interface Network (LIN) data bus is active. Depressing the heated seat switch provides a switch status message to the Cabin Compartment Node (CCN) via the LIN data bus. The CCN is responsible for supplying the LIN data bus message to the heated seat module, signaling the module to power the heated seat element of the selected seat and maintain the temperature setting. If the heated seat switch is depressed to a different position (Low or High) than the currently selected state, the CCN will go through the process again to change the temperature setting. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Description and Operation > Page 9520 Seat Heater Switch: Testing and Inspection HEATED SEAT SWITCH In order to obtain conclusive testing, the heated seat system and the Local Interface Network (LIN) data bus circuit must be checked. Any diagnosis of the heated seat system should begin with, the use of a scan tool and the appropriate diagnostic information. Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. NOTE: Vehicles equipped with the heated seat option utilize a low voltage cut-off feature. This feature turns off power to the heated seat system anytime vehicle voltage is below 11.7v or above 15.5v. Be certain to check the vehicle electrical system for proper voltage anytime the power seat system appears inoperative. Before any testing of the heated seat system is attempted, the battery should be fully-charged. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Removal Seat Heater Switch: Service and Repair Removal REMOVAL WARNING: On vehicles equipped with airbags, disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. NOTE: The heated seat switches are integral to the accessory switch bezel and cannot be serviced separately. 1. Disconnect and isolate the negative battery cable. 2. Remove the center bezel from the instrument panel and place it on a work bench. 3. Remove the screws that secure the accessory switch bank (4) to the back of the center bezel and remove the accessory switch bank. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Removal > Page 9523 Seat Heater Switch: Service and Repair Installation INSTALLATION NOTE: There are different instrument panel accessory switch banks available based on the option content of the vehicle. Ensure the accessory switch bank being installed matches the vehicle options. 1. Position the accessory switch bank (4) onto the back of the instrument panel center bezel. 2. Install the screws that secure the accessory switch bank to the center bezel. Tighten the screws to 1 Nm (8 in. lbs.). 3. Install the center bezel onto the instrument panel. 4. Reconnect the negative battery cable. 5. Verify heated seat system operation. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Customer Interest for Seat Track: > 23-008-08 > Feb > 08 > Interior - Seat Track Creak/Squeak Sound Seat Track: Customer Interest Interior - Seat Track Creak/Squeak Sound NUMBER: 23-008-08 GROUP: Body DATE: February 15, 2008 SUBJECT: Seat Track Creak/Squeak Sound OVERVIEW: This bulletin involves inspecting the seat track for metal to metal contact. The stationary track may have a rolled in rear corner causing interference. If this corner is contacting movable track, track adjustment is necessary. MODELS: 2007 - 2008 (JS41) Sebring/Avenger 2007 - 2008 (PM) Caliber 2007 - 2008 (MK) Compass/Patriot NOTE: This bulletin applies to models built before December 7, 2007 (MDH1207XX). SYMPTOM/CONDITION: Some vehicle occupants may experience a creak or squeak sound while driving with seat stationary and occupied. DIAGNOSIS: If the customer experiences the Symptom/Condition, inspect the seat track: 1. Move the affected seat to the full rear position. 2. Inspect the movable portion of the inner seat track lip for metal to metal contact (witness mark) with the stationary portion at the rear edge. Is there a witness mark indicating metal to metal contact between stationary and movable seat track? (Fig. 1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Customer Interest for Seat Track: > 23-008-08 > Feb > 08 > Interior - Seat Track Creak/Squeak Sound > Page 9532 a. No >>> This bulletin does not apply, further diagnosis is required. b. Yes >>> Perform the Repair Procedure. SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Move the affected seat to the full forward position. 2. Insert flat blade screwdriver or small pry bar between movable and stationary seat track at rear edge of track (Fig. 2). NOTE: Care should be taken not to over-adjust the track lip as this will cause interference on the other side of the upper track rail. CAUTION: Only slight adjustment is necessary. Pry lip of seat track just enough to achieve 0.5mm (0.020 In) of clearance. 3. Carefully pry the stationary rail lip toward the center of the seat by prying with screwdriver toward the outside of the seat track providing additional rail to rail clearance of 0.5mm (0.020 In) (Fig. 2). 4. Move the seat to the full rear position and verify clearance between rails. 5. Repeat for other affected seat track(s) as necessary. POLICY: Reimbursable within the provisions of the warranty. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Customer Interest for Seat Track: > 23-008-08 > Feb > 08 > Interior - Seat Track Creak/Squeak Sound > Page 9533 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Customer Interest for Seat Track: > 23-028-06A > Sep > 06 > Interior - Front Seat Cushion Loose/Clicks/Creaks Seat Track: Customer Interest Interior - Front Seat Cushion Loose/Clicks/Creaks NUMBER: 23-028-06 REV. A GROUP: Body DATE: September 20, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-028-06, DATED JULY 19, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES AN UPDATED OVERVIEW, VEHICLE BUILD DATE AND REPAIR PROCEDURE. SUBJECT: Clicking/Creaking Sound From Seat Or Looseness At Front Of Seat Cushion OVERVIEW: This bulletin involves adding electrical tape to the cushion pan attachment crosstube, installing new plastic brackets on the driver, passenger or both front seat(s) **and removing the pink foam block from both the lower front outboard side shields**. MODELS: 2007 (PM) Caliber 2007 (MK-49) Compass NOTE: **This bulletin applies to vehicles built before September 16, 2006 (MDH 0916XX).** SYMPTOM/CONDITION: The front cushion of the seat may feel loose and/or the seats may make a clicking or creaking sound when: i. Stopping and accelerating ii. Driving around corners DIAGNOSIS: If the sound is present for the driver or passenger front seats as described in the Symptom/Condition perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Customer Interest for Seat Track: > 23-028-06A > Sep > 06 > Interior - Front Seat Cushion Loose/Clicks/Creaks > Page 9538 2. Move the seat to the forward position. 3. From under the seat remove the bolts (2) and the straps (1). 4. Disconnect the electrical connector, if equipped. 5. Is tape already present on the crosstube? a. Yes - Proceed to Step # 7. b. No - Proceed to Step # 6. 6. Apply electrical tape per (Fig. 2). Wrap the tape around the crosstube, two wraps. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Customer Interest for Seat Track: > 23-028-06A > Sep > 06 > Interior - Front Seat Cushion Loose/Clicks/Creaks > Page 9539 7. Install new plastic brackets. NOTE: Each front seat has two brackets. 8. Reinstall metal straps and bolts, torque to 12.5Nm (110 in. lbs.) 9. **Is the vehicle a Compass built before September 16, 2006?** a. Yes - Proceed to Step # 10. b. No - Repair Complete. CAUTION: Do not pull side shield out too much in the next step. Only pull out enough to access the pink foam block. 10. **Using your hand pull the lower outboard side shield away from the seat frame (Fig. 3).** 11. **Remove the pink foam block from the lower outboard side shield.** 12. **Ensure the lower outboard side shield is snapped back into place.** NOTE: Be sure to perform this action for both front seats. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Customer Interest for Seat Track: > 23-028-06A > Sep > 06 > Interior - Front Seat Cushion Loose/Clicks/Creaks > Page 9540 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Customer Interest for Seat Track: > 23-024-06 > Jun > 06 > Interior - Front Seat Track Squeal/Click/Scraping Noises Seat Track: Customer Interest Interior - Front Seat Track Squeal/Click/Scraping Noises NUMBER: 23-024-06 GROUP: Body DATE: June 1, 2006 SUBJECT: Scraping, Clicking Or Squeal Sound From Seat Track OVERVIEW: This bulletin involves applying white lithium grease to the seat tracks for both front seats. MODELS: 2007 (PM) Caliber NOTE: This bulletin applies to vehicles built on or before March 6, 2006 (MDH 0306XX). SYMPTOM/CONDITION: The seats may make a squeal, clicking or scraping sound when: i. Stopping and accelerating ii. Driving around corners iii. Adjusting the seat This may be more noticeable at colder ambient temperatures. DIAGNOSIS: If the sound is present as described in the symptoms listed above perform the Repair Procedure. PARTS REQUIRED: NOTE: Do not use aerosol spray white lithium grease. This grease is not thick enough. NOTE: One tube of grease can treat more than 10 vehicles. REPAIR PROCEDURE: 1. Open door. 2. Slide seat to full back position. 3. Lubricate the seat track (p/n 68003883AA) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Customer Interest for Seat Track: > 23-024-06 > Jun > 06 > Interior - Front Seat Track Squeal/Click/Scraping Noises > Page 9545 a. Squeeze a dab of grease the size of a nickel between the driver side right outboard lower rail and the right outboard upper rail of the seat track (Fig. 1). b. Squeeze a dab of grease the size of a nickel between the driver side left outboard lower rail and the left outboard upper rail of the seat track (Fig. 1). 4. Move the seat back and forth a few times to distribute the grease along the track. 5. Repeat steps 4 and 5 for the passenger seat. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 23-008-08 > Feb > 08 > Interior - Seat Track Creak/Squeak Sound Seat Track: All Technical Service Bulletins Interior - Seat Track Creak/Squeak Sound NUMBER: 23-008-08 GROUP: Body DATE: February 15, 2008 SUBJECT: Seat Track Creak/Squeak Sound OVERVIEW: This bulletin involves inspecting the seat track for metal to metal contact. The stationary track may have a rolled in rear corner causing interference. If this corner is contacting movable track, track adjustment is necessary. MODELS: 2007 - 2008 (JS41) Sebring/Avenger 2007 - 2008 (PM) Caliber 2007 - 2008 (MK) Compass/Patriot NOTE: This bulletin applies to models built before December 7, 2007 (MDH1207XX). SYMPTOM/CONDITION: Some vehicle occupants may experience a creak or squeak sound while driving with seat stationary and occupied. DIAGNOSIS: If the customer experiences the Symptom/Condition, inspect the seat track: 1. Move the affected seat to the full rear position. 2. Inspect the movable portion of the inner seat track lip for metal to metal contact (witness mark) with the stationary portion at the rear edge. Is there a witness mark indicating metal to metal contact between stationary and movable seat track? (Fig. 1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 23-008-08 > Feb > 08 > Interior - Seat Track Creak/Squeak Sound > Page 9551 a. No >>> This bulletin does not apply, further diagnosis is required. b. Yes >>> Perform the Repair Procedure. SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Move the affected seat to the full forward position. 2. Insert flat blade screwdriver or small pry bar between movable and stationary seat track at rear edge of track (Fig. 2). NOTE: Care should be taken not to over-adjust the track lip as this will cause interference on the other side of the upper track rail. CAUTION: Only slight adjustment is necessary. Pry lip of seat track just enough to achieve 0.5mm (0.020 In) of clearance. 3. Carefully pry the stationary rail lip toward the center of the seat by prying with screwdriver toward the outside of the seat track providing additional rail to rail clearance of 0.5mm (0.020 In) (Fig. 2). 4. Move the seat to the full rear position and verify clearance between rails. 5. Repeat for other affected seat track(s) as necessary. POLICY: Reimbursable within the provisions of the warranty. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 23-008-08 > Feb > 08 > Interior - Seat Track Creak/Squeak Sound > Page 9552 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 23-028-06A > Sep > 06 > Interior - Front Seat Cushion Loose/Clicks/Creaks Seat Track: All Technical Service Bulletins Interior - Front Seat Cushion Loose/Clicks/Creaks NUMBER: 23-028-06 REV. A GROUP: Body DATE: September 20, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-028-06, DATED JULY 19, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES AN UPDATED OVERVIEW, VEHICLE BUILD DATE AND REPAIR PROCEDURE. SUBJECT: Clicking/Creaking Sound From Seat Or Looseness At Front Of Seat Cushion OVERVIEW: This bulletin involves adding electrical tape to the cushion pan attachment crosstube, installing new plastic brackets on the driver, passenger or both front seat(s) **and removing the pink foam block from both the lower front outboard side shields**. MODELS: 2007 (PM) Caliber 2007 (MK-49) Compass NOTE: **This bulletin applies to vehicles built before September 16, 2006 (MDH 0916XX).** SYMPTOM/CONDITION: The front cushion of the seat may feel loose and/or the seats may make a clicking or creaking sound when: i. Stopping and accelerating ii. Driving around corners DIAGNOSIS: If the sound is present for the driver or passenger front seats as described in the Symptom/Condition perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 23-028-06A > Sep > 06 > Interior - Front Seat Cushion Loose/Clicks/Creaks > Page 9557 2. Move the seat to the forward position. 3. From under the seat remove the bolts (2) and the straps (1). 4. Disconnect the electrical connector, if equipped. 5. Is tape already present on the crosstube? a. Yes - Proceed to Step # 7. b. No - Proceed to Step # 6. 6. Apply electrical tape per (Fig. 2). Wrap the tape around the crosstube, two wraps. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 23-028-06A > Sep > 06 > Interior - Front Seat Cushion Loose/Clicks/Creaks > Page 9558 7. Install new plastic brackets. NOTE: Each front seat has two brackets. 8. Reinstall metal straps and bolts, torque to 12.5Nm (110 in. lbs.) 9. **Is the vehicle a Compass built before September 16, 2006?** a. Yes - Proceed to Step # 10. b. No - Repair Complete. CAUTION: Do not pull side shield out too much in the next step. Only pull out enough to access the pink foam block. 10. **Using your hand pull the lower outboard side shield away from the seat frame (Fig. 3).** 11. **Remove the pink foam block from the lower outboard side shield.** 12. **Ensure the lower outboard side shield is snapped back into place.** NOTE: Be sure to perform this action for both front seats. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 23-028-06A > Sep > 06 > Interior - Front Seat Cushion Loose/Clicks/Creaks > Page 9559 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 23-024-06 > Jun > 06 > Interior - Front Seat Track Squeal/Click/Scraping Noises Seat Track: All Technical Service Bulletins Interior - Front Seat Track Squeal/Click/Scraping Noises NUMBER: 23-024-06 GROUP: Body DATE: June 1, 2006 SUBJECT: Scraping, Clicking Or Squeal Sound From Seat Track OVERVIEW: This bulletin involves applying white lithium grease to the seat tracks for both front seats. MODELS: 2007 (PM) Caliber NOTE: This bulletin applies to vehicles built on or before March 6, 2006 (MDH 0306XX). SYMPTOM/CONDITION: The seats may make a squeal, clicking or scraping sound when: i. Stopping and accelerating ii. Driving around corners iii. Adjusting the seat This may be more noticeable at colder ambient temperatures. DIAGNOSIS: If the sound is present as described in the symptoms listed above perform the Repair Procedure. PARTS REQUIRED: NOTE: Do not use aerosol spray white lithium grease. This grease is not thick enough. NOTE: One tube of grease can treat more than 10 vehicles. REPAIR PROCEDURE: 1. Open door. 2. Slide seat to full back position. 3. Lubricate the seat track (p/n 68003883AA) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 23-024-06 > Jun > 06 > Interior - Front Seat Track Squeal/Click/Scraping Noises > Page 9564 a. Squeeze a dab of grease the size of a nickel between the driver side right outboard lower rail and the right outboard upper rail of the seat track (Fig. 1). b. Squeeze a dab of grease the size of a nickel between the driver side left outboard lower rail and the left outboard upper rail of the seat track (Fig. 1). 4. Move the seat back and forth a few times to distribute the grease along the track. 5. Repeat steps 4 and 5 for the passenger seat. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection Power Door Lock Switch: Testing and Inspection DOOR LOCK SWITCH 1. Remove the switch. 2. Using an ohmmeter, refer to Door Lock Switch Test table to determine if switch resistance is correct in the Lock and Unlock switch positions. Refer to Wiring Diagrams for harness connector pin-outs. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Removal Power Door Lock Switch: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the front door bolster. 3. Disconnect the electrical harness connectors. 4. With the bolster on the bench, gently pry in on the tabs of the mirror switch and push through the front of the cover and remove. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Removal > Page 9571 Power Door Lock Switch: Service and Repair Installation INSTALLATION 1. Place the mirror switch in bolster opening and firmly snap into place. 2. Connect the electrical harness connectors. 3. Install the front door bolster. 4. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations Power Mirror Switch: Locations Component ID: 346 Component : SWITCH-MIRROR Connector: Name : SWITCH-MIRROR Color : BLACK # of pins : 10 Qualifier : (LHD) Pin Description Circuit 1-2-3 MIRROR COMMON DRIVER P76 20YL/PK 4 GROUND Z928 20BK/LG 5 FUSED B(+) (I.O.D.) A417 20RD/DG 6 RIGHT MIRROR VERTICAL DRIVER P72 20TN/GY 7 LEFT MIRROR VERTICAL DRIVER P71 20TN/DG 8 RIGHT MIRROR HORIZONTAL DRIVER P74 20TN/OR 9 LEFT MIRROR HORIZONTAL DRIVER P75 20TN/OR 10 - Component Location - 54 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 9575 Connector: Name : SWITCH-MIRROR Color : # of pins : 10 Qualifier : (RHD) Pin Description Circuit 1 FOLDING MIRROR RETURN P110 20LG/WT 2-3 MIRROR COMMON DRIVER P76 20YL/PK 4 GROUND Z928 20BK/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 9576 5 FUSED B(+) (I.O.D.) A417 20RD/DG 6 RIGHT MIRROR VERTICAL DRIVER P72 20TN/GY 7 LEFT MIRROR VERTICAL DRIVER P71 20TN/DG 8 RIGHT MIRROR HORIZONTAL DRIVER P74 20TN/OR 9 LEFT MIRROR HORIZONTAL DRIVER P75 20TN/OR 10 MIRROR-POWER FOLDING/UNFOLDING P699 20LG/DG Component Location - 54 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 9577 Power Mirror Switch: Diagrams Component ID: 346 Component : SWITCH-MIRROR Connector: Name : SWITCH-MIRROR Color : BLACK # of pins : 10 Qualifier : (LHD) Pin Description Circuit 1-2-3 MIRROR COMMON DRIVER P76 20YL/PK 4 GROUND Z928 20BK/LG 5 FUSED B(+) (I.O.D.) A417 20RD/DG 6 RIGHT MIRROR VERTICAL DRIVER P72 20TN/GY 7 LEFT MIRROR VERTICAL DRIVER P71 20TN/DG 8 RIGHT MIRROR HORIZONTAL DRIVER P74 20TN/OR 9 LEFT MIRROR HORIZONTAL DRIVER P75 20TN/OR 10 - Component Location - 54 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 9578 Connector: Name : SWITCH-MIRROR Color : # of pins : 10 Qualifier : (RHD) Pin Description Circuit 1 FOLDING MIRROR RETURN P110 20LG/WT 2-3 MIRROR COMMON DRIVER P76 20YL/PK 4 GROUND Z928 20BK/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 9579 5 FUSED B(+) (I.O.D.) A417 20RD/DG 6 RIGHT MIRROR VERTICAL DRIVER P72 20TN/GY 7 LEFT MIRROR VERTICAL DRIVER P71 20TN/DG 8 RIGHT MIRROR HORIZONTAL DRIVER P74 20TN/OR 9 LEFT MIRROR HORIZONTAL DRIVER P75 20TN/OR 10 MIRROR-POWER FOLDING/UNFOLDING P699 20LG/DG Component Location - 54 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 9580 Power Mirror Switch: Testing and Inspection POWER MIRROR SWITCH - LHD 1. Disconnect and isolate the battery negative cable. 2. Remove power mirror switch. 3. Using an ohmmeter, test for continuity between the terminals of the switch as shown in the Mirror Switch Test table. 4. If test results are not obtained as shown in the Mirror Switch Test table, replace the switch. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 9581 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 9582 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Removal Power Mirror Switch: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the front door bolster. 3. Disconnect the electrical harness connectors. 4. With the bolster on the bench, gently pry in on the tabs of the mirror switch and push through the front of the cover and remove. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Removal > Page 9585 Power Mirror Switch: Service and Repair Installation INSTALLATION 1. Place the mirror switch in bolster opening and firmly snap into place. 2. Connect the electrical harness connectors. 3. Install the front door bolster. 4. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Description Seat Heater Switch: Description and Operation Description DESCRIPTION The heated seat switches are located in the center stack (1) of the instrument panel. The switches are located on the outer edges of the accessory switch bank (2). If either of the switches is damaged or inoperative the complete accessory switch bank assembly must be replaced. When either of the heated seat switches are depressed a switch status message is sent to the Cab Compartment Node (CCN) or instrument cluster via the Local Interface Network (LIN) data bus. The CCN then sends a message via the LIN data bus to the heated seat module, signaling the module to energize the heating element for the selected seat. Amber Light Emitting Diodes (LEDs) in the top portion of each switch indicate the level of heat in use: Two LEDs are illuminated for high, one for low, and none for off. The heated seat module sends the LED illumination message to the CCN via the LIN data bus. The CCN then sends the LED illumination message to the accessory switch bank so that the appropriate LEDs are illuminated for any given heating level. Pressing the switch once will select high-level heating. Pressing the switch a second time will select low-level heating. Pressing the switch a third time will shut the heating elements off. The LED indicator lamps in each heated seat switch cannot be repaired. If the LED lamps are inoperative or damaged, or the switch is inoperative or damaged the complete accessory switch bank assembly must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Description > Page 9590 Seat Heater Switch: Description and Operation Operation OPERATION The heated seat switches are active any time the Local Interface Network (LIN) data bus is active. Depressing the heated seat switch provides a switch status message to the Cabin Compartment Node (CCN) via the LIN data bus. The CCN is responsible for supplying the LIN data bus message to the heated seat module, signaling the module to power the heated seat element of the selected seat and maintain the temperature setting. If the heated seat switch is depressed to a different position (Low or High) than the currently selected state, the CCN will go through the process again to change the temperature setting. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Page 9591 Seat Heater Switch: Testing and Inspection HEATED SEAT SWITCH In order to obtain conclusive testing, the heated seat system and the Local Interface Network (LIN) data bus circuit must be checked. Any diagnosis of the heated seat system should begin with, the use of a scan tool and the appropriate diagnostic information. Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. NOTE: Vehicles equipped with the heated seat option utilize a low voltage cut-off feature. This feature turns off power to the heated seat system anytime vehicle voltage is below 11.7v or above 15.5v. Be certain to check the vehicle electrical system for proper voltage anytime the power seat system appears inoperative. Before any testing of the heated seat system is attempted, the battery should be fully-charged. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Removal Seat Heater Switch: Service and Repair Removal REMOVAL WARNING: On vehicles equipped with airbags, disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. NOTE: The heated seat switches are integral to the accessory switch bezel and cannot be serviced separately. 1. Disconnect and isolate the negative battery cable. 2. Remove the center bezel from the instrument panel and place it on a work bench. 3. Remove the screws that secure the accessory switch bank (4) to the back of the center bezel and remove the accessory switch bank. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Removal > Page 9594 Seat Heater Switch: Service and Repair Installation INSTALLATION NOTE: There are different instrument panel accessory switch banks available based on the option content of the vehicle. Ensure the accessory switch bank being installed matches the vehicle options. 1. Position the accessory switch bank (4) onto the back of the instrument panel center bezel. 2. Install the screws that secure the accessory switch bank to the center bezel. Tighten the screws to 1 Nm (8 in. lbs.). 3. Install the center bezel onto the instrument panel. 4. Reconnect the negative battery cable. 5. Verify heated seat system operation. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Description and Operation > Description Sunroof / Moonroof Switch: Description and Operation Description DESCRIPTION The power sunroof switch (2) is a combination push-button and rocker switch module mounted in the Courtesy/Reading Lamp assembly (1). The sunroof switch is a direct contact unit that is directly wired to the sunroof motor/module assembly. The sunroof switch performs the following functions: - Power sunroof open (back of switch pushed) - Power sunroof express open (back of switch pushed and released) - Power sunroof closed (front of switch pushed) - Power sunroof express closed (front of switch pushed and released) - Power sunroof vent (switch center button pushed) The power sunroof switch cannot be repaired. If the individual components are damaged or inoperative the switch assembly must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Description and Operation > Description > Page 9599 Sunroof / Moonroof Switch: Description and Operation Operation OPERATION The sunroof is electrically operated from two switches located in the headliner on the courtesy/reading lamp assembly. The power sunroof switch is hard wired to the sunroof motor/module assembly. The "VENT" switch is a push button type switch and opens the sunroof to the vent position only. The other switch "OPEN/CLOSED" is a rocker type switch for opening and closing the sunroof. Pressing and releasing the open button once, the sunroof will express open and the wind deflector will raise. If the button is pressed a second time the sunroof will stop in that position. Pressing and releasing the close button once will express close the sunroof. If the close button is pressed a second time during the express close operation the sunroof will stop in that position. The switch is grounded at one terminal and receives a 5 volt signal from the sunroof motor/module on the remaining three terminals. The switch pulls down the 5 volt reference voltage from the module signaling it to perform the desired function. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Testing and Inspection > Control Switch Sunroof / Moonroof Switch: Testing and Inspection Control Switch CONTROL SWITCH The following test will determine if the sunroof control switch is operating properly. 1. Remove the sunroof control switch from the overhead console. 2. Using an ohmmeter, test the switch terminals for proper continuity using the table below. If any of the terminals do not show proper continuity, replace the sunroof control switch. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Testing and Inspection > Control Switch > Page 9602 Sunroof / Moonroof Switch: Testing and Inspection Sunroof Switch SUNROOF SWITCH For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Remove the power sunroof switch. 2. Disconnect the power sunroof switch wire harness connector. 3. With the ignition key in the "RUN" position check for 5 volts on the "OPEN", "CLOSE" and "VENT" circuits of the sunroof switch harness connector. If OK, go to STEP 4. If not OK, inspect the wiring harness and connectors between the motor/module and switch for damage and repair as necessary. 4. With the ignition key in the "OFF" position check for continuity between the ground circuit of the sunroof switch harness connector and a known good ground. Continuity should be present. If OK, go to STEP 5. If not OK, inspect the wiring harness and connector and repair the ground circuit as necessary. 5. Using an ohmmeter, test the continuity of the power sunroof switch in each switch position. If OK, inspect the wiring harness and connectors for damage and repair as necessary. If not OK, replace the power sunroof switch. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Removal Sunroof / Moonroof Switch: Service and Repair Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the courtesy/reading lamp lens (5). Insert a suitable flat bladed tool into the slot (6) in the courtesy/reading lamp assembly (2). Pivot the lens down and to the left to release the holding tab (4). 3. Using a suitable flat bladed tool, release the mounting tabs (5) from the sides of the sunroof control switch (4) and pull the switch down from the courtesy/reading lamp assembly (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Removal > Page 9605 4. Disconnect the electrical connector (3) from the sunroof control switch (4). 5. Remove the switch from the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Removal > Page 9606 Sunroof / Moonroof Switch: Service and Repair Installation INSTALLATION 1. Position the sunroof control switch (4) into the vehicle. 2. Connect the sunroof control switch electrical connector (3). 3. Insert the sunroof control switch (4) into the courtesy/reading lamp assembly (2). Push up on the switch until it is securely held in place by the mounting tabs (5). 4. Insert the mounting tab (4) on the lamp lens (5) into the right side of the lamp assembly and pivot the lens up until it snaps securely in place. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Removal > Page 9607 5. Connect the negative battery cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations Sound Proofing / Insulation: Locations SOUND DEADENER LOCATIONS Preferred Mopar Products: - Expandable Foam - Part No. 05142864AA - Dispenser - Part No. 05016570AA Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 9611 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 9612 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 9613 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 9614 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 9615 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 9616 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Spoiler > Component Information > Service and Repair > Removal Spoiler: Service and Repair Removal REMOVAL 1. Open liftgate. 2. Remove liftgate upper molding. 3. Remove 5 body plugs. 4. Remove nuts (3) on spoiler studs. 5. If equipped, remove satellite wire (2) connector (1). 6. Remove spoiler (5) from vehicle (4). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Spoiler > Component Information > Service and Repair > Removal > Page 9622 Spoiler: Service and Repair Installation INSTALLATION 1. Connect the washer hose (3) to the washer nozzle. 2. Connect the electrical connector (2) to the center high mount stop lamp and make sure the harness is install to the clip on the spoiler. NOTE: Make sure the adhesive patch areas are completely clean prior to installation of the spoiler. Due not touch any part of the adhesive tape once the cover strips has been removed. 3. Remove the adhesive cover strips, install spoiler (4) to the lift gate and press down on the areas of the spoiler that have the adhesive patches installed. 4. Install the nuts (1) to the spoiler studs tighten to 9.5 Nm (85 in. lbs.). 5. Install the body plugs. 6. Install the liftgate upper molding. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Removal Cowl Moulding / Trim: Service and Repair Removal REMOVAL 1. Remove the wiper arms (2). 2. Remove the hood seal (4). 3. Remove the screws (3) and remove the panel (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Removal > Page 9629 Cowl Moulding / Trim: Service and Repair Installation INSTALLATION 1. Position the end seals (1) into place. 2. Install the panel (2) and install the screws (3). 3. Install the hood seal (4). 4. Install the wiper arms (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Service and Repair > Removal Sunroof / Moonroof Weatherstrip: Service and Repair Removal REMOVAL 1. Remove sunroof glass panel. 2. Place glass panel on clean work area with the top side up. Support the glass assembly from underside to avoid bending or otherwise damaging the mounting tabs. 3. Grasp the seal (1) and pull seal away from the glass panel (2). The seal is a one piece seal. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Service and Repair > Removal > Page 9635 Sunroof / Moonroof Weatherstrip: Service and Repair Installation INSTALLATION NOTE: Always position seal seam on center of the passenger side of glass panel. 1. Place seal (1) into position. 2. Seat the seal into the glass channel fully. Using care working the seal around the glass (2), being careful not to over stretch the seal while installing. 3. Install the glass panel. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations Cruise Control Switch: Locations Component ID: 357 Component : SWITCH-SPEED CONTROL Connector: Name : SWITCH-SPEED CONTROL Color : BLACK # of pins : 3 Pin Description Circuit 1 S/C SIGNAL 2 V72 20PK 2 S/C SIGNAL 1 V71 20VT 3 S/C SWITCH GROUND V937 20YL Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 9640 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 9641 Cruise Control Switch: Diagrams Component ID: 357 Component : SWITCH-SPEED CONTROL Connector: Name : SWITCH-SPEED CONTROL Color : BLACK # of pins : 3 Pin Description Circuit 1 S/C SIGNAL 2 V72 20PK 2 S/C SIGNAL 1 V71 20VT 3 S/C SWITCH GROUND V937 20YL Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 9642 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Removal Cruise Control Switch: Service and Repair Removal REMOVAL WARNING: Do not place a non-deployed airbag face down on a hard surface, the airbag will propel into the air if accidentally deployed, and could result in serious or fatal injury. - Disconnect and isolate the battery negative (ground) cable before beginning steering wheel removal or installation. This will disable the front airbag system. Failure to disconnect the battery could result in accidental front airbag module deployment and possible personal injury. - Allow the front airbag system capacitor to discharge for two minutes before removing the steering wheel or any front airbag system component. The speed control switches is mounted in the steering wheel and wired through the clock spring device under the airbag module. 1. Adjust the steering wheel so that the tires are in the STRAIGHT-AHEAD position. 2. Remove the negative battery cable. 3. Turn off ignition. 4. Remove air bag. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Removal > Page 9645 5. Disconnect the connector from the clockspring. 6. Remove the three mounting fasteners. 7. Remove the horn switch. 8. Remove 2 speed control switch mounting screws. 9. Disconnect the electrical connector. 10. Remove switch. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Removal > Page 9646 Cruise Control Switch: Service and Repair Installation INSTALLATION The speed control switch is mounted in the steering wheel and wired through the clock spring device under the airbag module. 1. Connect the electrical connector to speed control switch. 2. Install the 2 speed control screw. 3. Tighten the screws (1) to 1.6 Nm (15 in. lbs.). Make sure rubber seal is in place around switch. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Removal > Page 9647 4. Install the horn switch. 5. Install the three mounting fasteners. 6. Connect the electrical connector to the clockspring. 7. Install the driver airbag (3). WARNING: Do not connect battery negative cable yet. 8. Reconnect battery using Airbag System Test procedure in Restraints. 9. Close hood. 10. Verify vehicle and system operation. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations Cruise Control Switch: Locations Component ID: 357 Component : SWITCH-SPEED CONTROL Connector: Name : SWITCH-SPEED CONTROL Color : BLACK # of pins : 3 Pin Description Circuit 1 S/C SIGNAL 2 V72 20PK 2 S/C SIGNAL 1 V71 20VT 3 S/C SWITCH GROUND V937 20YL Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 9652 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 9653 Cruise Control Switch: Diagrams Component ID: 357 Component : SWITCH-SPEED CONTROL Connector: Name : SWITCH-SPEED CONTROL Color : BLACK # of pins : 3 Pin Description Circuit 1 S/C SIGNAL 2 V72 20PK 2 S/C SIGNAL 1 V71 20VT 3 S/C SWITCH GROUND V937 20YL Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 9654 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Removal Cruise Control Switch: Service and Repair Removal REMOVAL WARNING: Do not place a non-deployed airbag face down on a hard surface, the airbag will propel into the air if accidentally deployed, and could result in serious or fatal injury. - Disconnect and isolate the battery negative (ground) cable before beginning steering wheel removal or installation. This will disable the front airbag system. Failure to disconnect the battery could result in accidental front airbag module deployment and possible personal injury. - Allow the front airbag system capacitor to discharge for two minutes before removing the steering wheel or any front airbag system component. The speed control switches is mounted in the steering wheel and wired through the clock spring device under the airbag module. 1. Adjust the steering wheel so that the tires are in the STRAIGHT-AHEAD position. 2. Remove the negative battery cable. 3. Turn off ignition. 4. Remove air bag. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Removal > Page 9657 5. Disconnect the connector from the clockspring. 6. Remove the three mounting fasteners. 7. Remove the horn switch. 8. Remove 2 speed control switch mounting screws. 9. Disconnect the electrical connector. 10. Remove switch. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Removal > Page 9658 Cruise Control Switch: Service and Repair Installation INSTALLATION The speed control switch is mounted in the steering wheel and wired through the clock spring device under the airbag module. 1. Connect the electrical connector to speed control switch. 2. Install the 2 speed control screw. 3. Tighten the screws (1) to 1.6 Nm (15 in. lbs.). Make sure rubber seal is in place around switch. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Removal > Page 9659 4. Install the horn switch. 5. Install the three mounting fasteners. 6. Connect the electrical connector to the clockspring. 7. Install the driver airbag (3). WARNING: Do not connect battery negative cable yet. 8. Reconnect battery using Airbag System Test procedure in Restraints. 9. Close hood. 10. Verify vehicle and system operation. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > Description Audible Warning Device: Description and Operation Description DESCRIPTION The chime software is located within, and serviced with the instrument cluster. The chime warning system uses an electromechanical transducer and an electromechanical relay that are soldered onto the electronic circuit board inside of the Electromechanical Instrument Cluster (EMIC) to provide audible indications of various vehicle conditions that may require the attention of the vehicle operator or occupants. The EMIC also includes the hardware and software necessary to serve as the electronic body control module and is sometimes referred to as the Cab Compartment Node or CCN. The electromechanical transducer generates beep tones and chime tones, while the electromechanical relay generates click tones to emulate the sounds associated with conventional turn signal and hazard warning flasher operation. The microprocessor-based EMIC utilizes electronic chime request messages received from other modules in the vehicle over the Controller Area Network (CAN) data bus along with hard wired inputs to monitor many sensors and switches throughout the vehicle. In response to those inputs, the circuitry and programming of the EMIC allow it to control the audible outputs that are produced through its on-board transducer and relay. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > Description > Page 9665 Audible Warning Device: Description and Operation Operation OPERATION CHIME WARNING SYSTEM The chime warning system operates on battery voltage received through a fuse in the Junction Block (JB) on a non-switched fused B(+) circuit so that the system may operate regardless of the ignition switch position. The chime warning system also monitors the ignition switch position so that some chime features are functional only with the ignition switch in the On position, while others are functional regardless of the ignition switch position. The chime warning system provides an audible indication to the vehicle operator or occupants under the following conditions: - Airbag Indicator Warning - The Cab Compartment Node (CCN) will generate one short chime when the ignition switch is in the On position, and an electronic message is received over the Controller Area Network (CAN) data bus from the Occupant Restraint Controller (ORC) requesting "Airbag" indicator illumination. This warning will only occur following completion of the "Airbag" indicator bulb test, and will only occur once during any ignition cycle. - Door Ajar Indicator Warning - The CCN will generate one short chime when the ignition switch is in the On position, a hard wired input is received indicating that the status of any door ajar switch has changed, and an electronic message is received over the CAN data bus indicating that the vehicle is moving. Door ajar chime occurs only if the door ajar status is true. - Door opened and - Ignition in RUN position and - Vehicle speed is present - Fasten Seat Belt Indicator Warning - The CCN will generate repetitive chimes at a slow rate to announce that a hard wired input from the seat belt switch indicates that the driver side front seat belt is not fastened with the ignition switch in the On position. The chime warning system also supports the enhanced seat belt reminder (beltminder) when this feature is enabled. NOTE: If the vehicle is equipped with the Occupant Classification System (OCS), this will apply to the front passenger seatbelt as well. There are two different Fasten Seatbelt Reminder announcements incorporated into the cluster's logic, a Non-enhanced announcement and an Enhanced announcement. When the Enhanced announcement is DISABLED: - The cluster will chime five times (not greater than six seconds) and illuminate the Seatbelt Lamp after turning the ignition to the run/start position if the driver/passenger seatbelt is unbuckled. When the Enhanced announcement is ENABLED; - The cluster will chime continuously at a slow rate for a period of 6 seconds and illuminate the Seatbelt Lamp after turning the ignition to the run/start position if the driver/passenger seatbelt is unbuckled. After 6 seconds the chime will stop, but the Seatbelt Lamp will stay illuminated. If the ignition is in the run position for a period greater than 60 seconds, and the driver/passenger seatbelt is unbuckled, and the vehicle's speed is greater than 5 mph (8 km/h) in a forward gear, the Enhanced Fasten Seatbelt Reminder will activate. This will cause the Seatbelt Lamp to blink and a slow continuous chime to sound for 5 seconds. After 5 seconds, the chime will stop, but the lamp will remain illuminated for an additional 3 seconds. The Enhanced Seatbelt Reminder cycles for a total of 12 times (96 seconds). After the 12th time, the Seatbelt Lamp will remain on without any chime. Buckling the driver/passenger seatbelt at anytime will cancel the Fasten Seatbelt Reminder announcement. The seatbelt indicator includes a programmable enhanced seatbelt reminder or "beltminder" feature that is enabled when the vehicle is shipped from the factory. This beltminder feature can be disabled and enabled by the customer using a specific programming event sequence, or by the dealer using a diagnostic scan tool. - Gate Ajar Indicator Warning - The CCN will generate one short chime when the ignition switch is in the On position, a hard wired input is received indicating that the status of the liftgate ajar switch has changed (switch position has to change to true), and an electronic message is received over the CAN data bus indicating that the vehicle is moving. - Head/Park Lamps-On Warning - The CCN will generate repetitive chimes at a fast rate to indicate that hard wired inputs from the driver door ajar switch, the headlamp switch, and the ignition switch indicate that the exterior lamps are turned On with the driver side front door opened and the ignition switch in the Off position. The chimes will continue to sound until the exterior lamps are turned Off, the driver side front door is closed, or the ignition switch is turned to the On position, whichever occurs first. - Key-In-Ignition Warning - The CCN will generate repetitive chimes at a fast rate to indicate that hard wired inputs from the driver door ajar switch, the ignition switch, and the key-in ignition switch circuitry of the ignition switch indicate that the key is in the ignition in the lock position with the driver side front door open and the ignition switch in the Off position. The chimes will continue to sound until the key is removed from the ignition lock cylinder, the driver side front door is closed, or the ignition switch is turned to the On position, whichever occurs first. - Low Fuel Indicator Warning - The CCN will generate one short chime when the low fuel indicator is illuminated by the instrument cluster circuitry. This chime will only occur once during any ignition cycle. - Park Brake Reminder - The CCN will generate one short chime to announce that the hard wired input from the park brake switch and a vehicle Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > Description > Page 9666 speed message input received over the CAN data bus indicate that the park brake is applied and the vehicle is moving. This chime will repeat each time the input conditions are met. - Sentry Key "Customer Learn" Mode Announcement - The CCN will generate one short chime to confirm that an electronic "Customer Learn" mode message has been received over the CAN data bus to indicate that the Sentry Key Remote Entry Module (SKREEM) is prepared for programming additional sentry key transponders. This chime feature is only active on vehicles equipped with the optional Sentry Key system, and sold in a market where "Customer Learn" programming is an allowed feature. - Turn Signal/Hazard Warning Flasher Emulation - The CCN relay will generate repetitive clicks at a slow rate to emulate an electromechanical flasher when the turn signal or hazard warning system are operating. The CCN relay will generate repetitive clicks at a fast rate to indicate that the right or left turn signal are operating with one or more bulbs inoperative. In either case, the clicks will continue until the turn signal and hazard warning systems are turned off. - Turn Signal On Warning - The CCN will generate repetitive chimes at a slow rate to indicate that a turn signal has been active continuously for 1.6 kilometers (1 mile) with the vehicle speed greater than 22 kilometers-per-hour (15 miles-per hour). Vehicles built for markets other than the United States and Canada have a revised distance threshold of 4 kilometers for this feature. The chime will continue until the turn signal input becomes inactive or until the vehicle speed message indicates that the speed is less than 22 kilometers-per-hour (15 miles-per-hour), whichever occurs first. The hazard warning flashers will not activate this chime feature. - Warning Indicator Announcement - The CCN will generate one short chime each time the Malfunction Indicator or MIL lamp is illuminated by the instrument cluster circuitry. The check gauges indicator may be illuminated when any critical engine or transmission systems are operating outside of their normal parameters. The instrument cluster monitors electronic messages received over the CAN data bus to determine when to illuminate the check gauges indicator. The CCN provides chime service for all available features in the chime warning system. The CCN relies upon its internal programming, numerous hard wired inputs, and electronic message inputs received from other modules over the CAN data bus network to provide the chime warning system features. The internal programming of the CCN determines the priority of each chime request input that is received, as well as the rate and duration of each chime that is to be generated. The hard wired chime warning system inputs to the CCN may be diagnosed and tested using conventional diagnostic tools and procedures. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the CCN, the CAN data bus, or the electronic messages received by the CCN from other modules. The most reliable, efficient and accurate means to diagnose the CCN, the CAN/LIN data bus, or the electronic message inputs used for the chime warning system requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Chime/Buzzer System Audible Warning Device: Testing and Inspection Chime/Buzzer System CHIME/BUZZER SYSTEM The hard wired chime warning system inputs to the Electromechanical Instrument Cluster (EMIC), as well as other hard wired circuits for this system may be diagnosed and tested using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the EMIC, the Controller Area Network (CAN) data bus, or the electronic message inputs used by the EMIC to provide chime warning system service. The most reliable, efficient, and accurate means to diagnose the EMIC, the CAN data bus, and the electronic message inputs for the chime warning system requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Chime/Buzzer System > Page 9669 Audible Warning Device: Testing and Inspection Fasten Seat Belts FASTEN SEAT BELTS To test the fasten seat belts function, turn the ignition switch to the ON position with the driver's seat belt unbuckled and fully retracted. The seat belt warning lamp should light for four to eight seconds and the tone should sound three to five times. If the lamp does not light, check the connection at the seat belt retractor. Replace as necessary. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Testing and Inspection Brake Warning Indicator: Testing and Inspection BRAKE/PARK BRAKE INDICATOR The brake/park brake indicator illuminates when the parking brake is applied with the ignition switch turned to the ON position refer to the PARK BRAKE SWITCH TEST table). The same lamp will also illuminate if one of the two (hydraulic or ABS) service brake systems fail when the brake pedal is applied. TO TEST THE SYSTEM: - As the ignition switch is turned to the START position, the lamp should light. - Turn ignition switch to the ON position and apply the parking brake. The lamp should light. IF LAMPS FAILS TO LIGHT, INSPECT FOR: - A broken or disconnected wire at the switch - Defective switch - A burned out Light Emitting Diode (LED) - A damaged circuit board To test the service brake warning system, refer to Brakes, Diagnosis and Testing, Base Brake System Diagnosis Charts, Red Brake Warning Lamp. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: Provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9677 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9678 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9679 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9680 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9681 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9682 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9683 5. Release the Secondary Terminal Lock, if required (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9684 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9685 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9686 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9687 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9688 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9689 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9690 Cigarette Lighter: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9691 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9692 STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9693 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9694 Cigarette Lighter: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-41-02 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9695 8w-41-03 Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Description and Operation > Description Cigarette Lighter: Description and Operation Description DESCRIPTION INSTRUMENT PANEL MOUNTED An instrument panel mounted cigar lighter/power outlet receptacle is optional equipment on this model. On models equipped with the optional Smoker's Package, the cigar lighter knob and heating element are included. On models without the Smoker's Package, the cigar lighter receptacle is equipped with a snap fit plastic cap and is treated as an auxiliary power outlet. The cigar lighter receptacle is installed in the instrument panel accessory switch bezel, which is located near the bottom of the instrument panel center stack area, below the radio. The cigar lighter base is secured by a snap fit within the center lower bezel. This power outlet has a constant 12 volt battery feed. The cigar lighter receptacle is serviced with the accessory switch bezel and if defective, the entire switch bezel must be replaced. The plastic cap and the knob and heating element unit are available for service replacement. These components cannot be repaired and, if faulty or damaged, they must be replaced. FRONT CONSOLE AND REAR CARGO MOUNTED A front console mounted power outlet is standard equipment and a rear cargo area power outlet is optional equipment on this model. The front console mounted power outlet is mounted near the front of the console just in front of the cup holders. This outlet can be used as a cigar lighter or power outlet, but only has 12 volt battery voltage when the ignition is in the ON or ACC positions. The rear power outlet is installed in the right rear quarter trim panel, near the spare tire jack (2). The power outlet base and mount are secured by a snap fit within the quarter trim panel. A plastic protective cap snaps into the power outlet base when the power outlet is not being used, and hangs from the power outlet base mount by an integral bail strap while the power outlet is in use. While the power outlet is very similar to a cigar lighter base unit, it does not include the two small spring-clip retainers inside the bottom of the receptacle shell that are used to secure the cigar lighter heating element to the insulated contact. It has 12 volt battery voltage when the ignition is in the ON or ACC positions. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Description and Operation > Description > Page 9698 Cigarette Lighter: Description and Operation Operation OPERATION CIGAR LIGHTER/POWER OUTLET The cigar lighter consists of two major components: a knob and heating element unit, and the cigar lighter base or receptacle shell. The receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The cigar lighter knob and heating element are encased within a spring-loaded housing, which also features a sliding protective heat shield. When the knob and heating element are inserted in the receptacle shell, the heating element resistor coil is grounded through its housing to the receptacle shell. If the cigar lighter knob is pushed inward, the heat shield slides up toward the knob exposing the heating element, and the heating element extends from the housing toward the insulated contact in the bottom of the receptacle shell. Two small spring-clip retainers are located on either side of the insulated contact inside the bottom of the receptacle shell. These clips engage and hold the heating element against the insulated contact long enough for the resistor coil to heat up. When the heating element is engaged with the contact, battery current can flow through the resistor coil to ground, causing the resistor coil to heat. When the resistor coil becomes sufficiently heated, excess heat radiates from the heating element causing the spring-clips to expand. Once the spring-clips expand far enough to release the heating element, the spring-loaded housing forces the knob and heating element to pop back outward to their relaxed position. When the cigar lighter knob and element are pulled out of the receptacle shell, the protective heat shield slides downward on the housing so that the heating element is recessed and shielded around its circumference for safety. POWER OUTLET The power outlet base or receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The power outlet receives battery voltage from a fuse in the Totally Integrated Power Module (TIPM) through a fuse in the fuse block when the ignition is in the ON or ACC positions. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Service and Repair > Removal Cigarette Lighter: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Look inside and note position of the retaining bosses (1). 3. Using special tool 9857 Power Outlet Remover. Insert the tool forcing the bosses out of base. 4. Pull out the base through mounting ring by gently rocking the tool (3). 5. Disconnect the base wires. 6. Set base aside and remove base mount ring. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Service and Repair > Removal > Page 9701 Cigarette Lighter: Service and Repair Installation INSTALLATION 1. Position mount ring to the instrument panel and feed the wires through ring. Index the cap and the mount ring with the index tab at 9 o'clock to the key in the instrument panel. Install the ring. 2. Connect wires to base. Orient base alignment rib at 11 o'clock to mate the groove in mount ring at the same location. 3. Push base into the bezel till it locks. 4. Install cigar lighter cap. 5. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Locations Compass: Locations Component ID: 147 Component : MODULE-COMPASS Connector: Name : MODULE-COMPASS Color : BLACK # of pins : 4 Pin Description Circuit 1-2 LIN BUS D506 20WT/DG 3 GROUND Z937 20BK/YL 4 FUSED IGNITION SWITCH OUTPUT (RUN) F929 20PK/RD Component Location - 29 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Locations > Page 9705 Fig. 29 Component Location - 32 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Locations > Page 9706 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Locations > Page 9707 Compass: Diagrams Component ID: 147 Component : MODULE-COMPASS Connector: Name : MODULE-COMPASS Color : BLACK # of pins : 4 Pin Description Circuit 1-2 LIN BUS D506 20WT/DG 3 GROUND Z937 20BK/YL 4 FUSED IGNITION SWITCH OUTPUT (RUN) F929 20PK/RD Component Location - 29 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Locations > Page 9708 Fig. 29 Component Location - 32 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Locations > Page 9709 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Compass Calibration Compass: Adjustments Compass Calibration COMPASS CALIBRATION CAUTION: Do not place any external magnets, such as magnetic roof mount antennas, in the vicinity of the compass. Do not place any electronic devices (cell phones, laptop computers, PDA's, portable DVD players, etc), on or near the instrument panel as the Remote Compass Module (RCM) performance may be effected. Do not use magnetic tools when servicing the RCM. The electronic compass unit features a continuous self-calibrating feature. This feature automatically updates the compass calibration as the vehicle is driven. This allows the compass unit to compensate for small changes in the residual magnetism that the vehicle may acquire during normal use. If the compass readings appear to be erratic or the Electronic Vehicle Information Center (EVIC) displays "CAL", perform the following calibration procedure. Also, any time a new RCM is installed, it must be calibrated using this procedure. Calibrate the compass manually as follows: NOTE: Do not attempt to calibrate the compass near large metal objects such as other vehicles, large buildings, or bridges; or, near overhead or underground power lines. 1. Start the engine but leave the vehicle in "PARK". 2. Continue to depress and release the STEP button (28) until the "Personal Settings" menu is displayed. 3. Once in the "Personal Settings" menu depress and release the STEP button (28) several times until "Calibrate Compass (Yes)" is displayed. 4. A long (longer than two seconds) STEP button press will place the compass in calibration mode. The "Cal" indicator will change from flashing to on continuously in the EVIC display (29) to indicate that the compass is now in the calibration mode and that the vehicle can now be driven to calibrate. (A short STEP button press from the "Calibrate Compass (Yes)" screen will exit the EVIC Customer Programmable features, and return it to its normal operating mode). 5. To complete the compass calibration, drive the vehicle in one or more complete 360 degree circles under 5 mph (8 km/h) in an area free of large metal objects such as other vehicles, large buildings, or bridges; or, near overhead or underground power lines, until the "CAL" indicator turns off. The compass will now function normally. NOTE: If the compass display indicates an inaccurate compass heading or the display is locked up, the RCM may be inoperative or the vehicle may need to be demagnetized. Perform the Compass Demagnetizing Procedure prior to performing any system diagnosis. NOTE: If the compass display indicates dashes "- -" the RCM may be inoperative or the vehicle may need to be demagnetized. Perform the Compass Demagnetizing Procedure prior to performing any system diagnosis. NOTE: If the "CAL" message remains in the display or if the compass heading is inaccurate following the calibration procedure and there are no internal compass faults, either there is excessive magnetism near the compass, or the unit is inoperative. Repeat the calibration procedure at least one more time prior to performing any system diagnosis. NOTE: If the wrong direction is still indicated in the compass display, the area selected for calibration may be too close to a strong magnetic field. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Compass Calibration > Page 9712 Repeat the calibration procedure in another location. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Compass Calibration > Page 9713 Compass: Adjustments Compass Variance Adjustment COMPASS VARIANCE ADJUSTMENT Compass variance, also known as magnetic declination, is the difference in angle between magnetic north and geographic north. In some geographic locations, the difference between magnetic and geographic north is great enough to cause the compass to give inaccurate readings. To optimize compass accuracy, the compass variance should be properly set according to the compass variance map zone for the region that the vehicle is in. To set the compass variance: 1. Using the Variance Settings map, find your geographic location and note the zone number. 2. Turn the ignition switch to the On position. 3. Continue to depress and release the STEP button (28) until the "Personal Settings" menu is displayed. 4. Once in the "Personal Settings" menu depress and release the STEP button (28) several times until "Compass Variance" is displayed. The "Compass Variance" message and the current variance zone number will be displayed. The default variance zone is 8. NOTE: During programming, the Zone value will wrap around from Zone 15 to Zone 1. 5. To change the zone, press and hold (longer than two seconds) the STEP button to increment the variance one step. Repeat as necessary, with individual long (longer than two seconds) STEP button presses for each increment, until the desired variance is achieved. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Compass Calibration > Page 9714 6. To exit the Variance Programming, press the STEP button with a short (less than one second) button press. 7. Confirm that the correct directions are now indicated by the compass. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Procedures Compass: Procedures COMPASS DEMAGNETIZING A degaussing tool (Special Tool 6029) is used to demagnetize, or degauss, the roof panel above the overhead console. Equivalent units must be rated as continuous duty for 110/115 volts and 60 Hz. They must also have a field strength of over 350 gauss at 7 millimeters (0.25 inch) beyond the tip of the probe. To demagnetize the roof panel proceed as follows: 1. Be certain that the ignition switch is in the Off position, before you begin the demagnetizing procedure. 2. Place a piece of paper approximately 22 by 28 centimeters (8.5 by 11 inches), oriented on the vehicle lengthwise from front to rear, on the center line of the roof at the windshield header. The purpose of the paper is to protect the roof panel from scratches, and to define the area to be demagnetized. 3. Connect the degaussing tool to an electrical outlet, while keeping the tool at least 61 centimeters (2 feet) away from the compass unit. 4. Slowly approach the center line of the roof panel at the windshield header, with the degaussing tool connected. 5. Contact the roof panel with the plastic coated tip of the degaussing tool. Be sure that the template is in place to avoid scratching the roof panel. Using a slow, back-and-forth sweeping motion, and allowing 13 millimeters (0.50 inch) between passes, move the tool at least 11 centimeters (4 inches) to each side of the roof center line, and 28 centimeters (11 inches) back from the windshield header. 6. With the degaussing tool still energized, slowly back it away from the roof panel. When the tip of the tool is at least 61 centimeters (2 feet) from the roof panel, disconnect the tool. 7. Calibrate the compass and adjust the compass variance. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Procedures > Page 9717 Compass: Removal and Replacement Removal - Remote Compass Module REMOVAL - REMOTE COMPASS MODULE WARNING: On vehicles equipped with airbags, disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. NOTE: RHD model shown in illustration. LHD model similar. 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel upper panel. 3. Remove the screws (6) securing the Remote Compass Module (RCM) (5) to the instrument panel. 4. Disconnect the RCM electrical connector (1) and remove the RCM from the vehicle. Installation - Remote Compass Module INSTALLATION - REMOTE COMPASS MODULE NOTE: RHD model shown in illustration. LHD model similar. 1. Position the Remote Compass Module (RCM) (5) on top of the instrument panel. 2. Install the screws (6) that secure the RCM to the instrument panel. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Procedures > Page 9718 3. Connect the RCM electrical connector (1). 4. Install the instrument panel upper panel. 5. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions Driver/Vehicle Information Display: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: Provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9723 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9724 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9725 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9726 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9727 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9728 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9729 5. Release the Secondary Terminal Lock, if required (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9730 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9731 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9732 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9733 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9734 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9735 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9736 Driver/Vehicle Information Display: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9737 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9738 STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9739 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9740 Driver/Vehicle Information Display: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-49-02 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9741 8w-49-03 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9742 8w-49-04 Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Description Driver/Vehicle Information Display: Description and Operation Description DESCRIPTION The base instrument cluster can be identified by the single TRIP SHAFT button (18) located to the left of the Temperature Gauge (3). The odometer display (15) doubles as the outside air temperature display when selected by toggling through the odometer menu using the TRIP SHAFT button. The Electronic Vehicle Information Center (EVIC) features a driver-interactive display (29). The display is located in the lower left part of the instrument cluster below the fuel and engine temperature gauges (1 and 3). This system conveniently allows the driver to select a variety of useful information by pressing the STEP button (28) to the right of the EVIC display. The EVIC displays information related to the following: - System Status - Vehicle information warning message displays - Personal Settings (customer programmable features) - Compass display - Outside temperature display - Trip computer functions - U-Connect hands-free communication system displays - If Equipped - Navigation system screens - If Equipped - Audio mode display The EVIC system is comprised of several different components. Those components are: - Instrument Cluster - EVIC STEP Button Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Description > Page 9745 - Ambient Temperature Sensor - Remote Compass Module (RCM) - Controller Area Network (CAN) Data Bus - Local Interface Network (LIN) Data Bus The EVIC display and STEP button are part of the Instrument Cluster assembly and cannot be serviced as separate components. If the display or button are inoperative the complete Instrument Cluster assembly must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Description > Page 9746 Driver/Vehicle Information Display: Description and Operation Operation OPERATION The Electronic Vehicle Information Center (EVIC) uses both non-switched and ignition switched sources of battery current so that some of its features remain operational at any time, while others may only operate with the ignition switch in the On position. When the ignition switch is turned to the On position, the EVIC display (29) will return to the last function being displayed before the ignition was turned to the Off position. The EVIC system is comprised of several different components that communicate over the Controller Area Network (CAN) and Local Interface Network (LIN) Data Buses. If the system is inoperative a scan tool and the appropriate diagnostic information must be used to diagnose the system and related data buses. The instrument cluster STEP button (28) is used to operate the different functions of the EVIC system. Pressing and releasing the STEP button will scroll through the following displays: - Compass/Temperature/Audio - Average Fuel Economy - Distance to Empty - Elapsed Time - Personal Settings Once a particular system is displayed, short and long presses of the STEP button will move the EVIC through the system menu. Pressing and holding the STEP button once will clear the resettable function currently being displayed. Reset will only occur if a resettable function is currently being displayed. To reset all resettable functions, press and release the STEP button a second time within 3 seconds of resetting the currently displayed function (Reset ALL will be displayed during this 3 second window). EVIC DISPLAY MODES SYSTEM STATUS MODE System display mode displays warnings and user interaction messages on the EVIC display (29). The driver can scroll to view multiple messages by using the STEP button. When the appropriate conditions exist, the EVIC displays the following messages: - Turn Signal On (with a continuous warning chime) - Left Front Turn Signal Lamp Out (with a single chime) - Left Rear Turn Signal Lamp Out (with a single chime) - Right Front Turn Signal Lamp Out (with a single chime) - Right Rear Turn Signal Lamp Out (with a single chime) - Personal Settings Not Available - Vehicle Not in Park (automatic transmissions) or vehicle in motion (manual transmissions) - Left/Right Front Door Ajar (one or more, with a single chime if speed is above 1 mph (1.6 km/h)) - Left/Right Rear Door Ajar (one or more, with a single chime if speed is above 1 mph (1.6 km/h)) - Door(s) Ajar (with a single chime if vehicle is in motion) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Description > Page 9747 - Trunk Ajar (with a single chime) - Headlamps On/Lights On With Key Out Of Ignition. COMPASS/TEMPERATURE/AUDIO Compass heading and outside temperature are displayed at the top of the EVIC display screen. On the lower half of the screen the audio mode is displayed along with the odometer. One of eight compass headings to indicate the direction the vehicle is facing (N, S, E, W, NE, NW, SE, SW) and to select one of 15 compass variance settings. Outside temperature is displayed in ° C (degrees Celsius) or ° F (degrees Fahrenheit). Audio mode can display any one of 12 radio station preset frequencies, CD disc number, CD track number, tape, and one of 200 Satellite Radio Channels - if equipped. For information regarding the compass, refer to Personal Settings (Customer Programmable Features). AVERAGE FUEL ECONOMY Shows the average fuel economy since the last reset. When the fuel economy is reset, the display will read "RESET" or show dashes for two seconds. Then, the history information will be erased, and the averaging will continue from where it was before the reset. DISTANCE TO EMPTY (DTE) NOTE: Significant changes in driving style or vehicle loading will greatly affect the actual drivable distance of the vehicle, regardless of the DTE displayed value. Shows the estimated distance that can be travelled with the fuel remaining in the tank. This estimated distance is determined by a weighted average of the instantaneous and average fuel economy, according to the current fuel tank level. This is not resettable. When the DTE value is less than 30 miles (48 kilometers) estimated driving distance, the DTE display will change to a text display of "LOW FUEL". This display will continue until the vehicle runs out of fuel. Adding a significant amount of fuel to the vehicle will turn off the "LOW FUEL" text and a new DTE value will be displayed, based on the current values in the DTE calculation and the current fuel tank level. ELAPSED TIME Shows the total elapsed time of travel since the last reset when the ignition switch is in the ACC position. Elapsed time will increment when the ignition switch is in the ON or START position. HANDS FREE TELEPHONE MODE - IF EQUIPPED Provides the following information and features for the optional hands-free communications system: - Phone status: idle, voice mail, roaming, battery strength and signal strength in increments of 20 percent - Call status: Incoming call, connecting, connected, air time in minutes and seconds, call ended, busy, call failed, roaming and no phone connection - Caller ID phone number display PERSONAL SETTINGS MODE (CUSTOMER PROGRAMMABLE FEATURES) Allows the driver to set and recall features when the transmission is in Park by pressing and releasing the STEP button until Personal Settings is displayed in the EVIC. The following personal settings can be set and recalled: - Language: English, Spanish and French (domestic markets) German and Italian (export markets) - Lock doors automatically at 15 mph (24 km/h), On or Off - Unlock door automatically on exit, On or Off - Remote Keyless Entry unlock driver door on first press or unlock all doors on first press - Sound horn with Remote Keyless Entry Lock, On or Off - Turn headlamps on with Remote Keyless Entry Lock, On or Off - Delay turning headlamps off for 0, 30, 60 or 90 seconds - Key-Off Power Delay (delay power off to accessories until exit off, 45-seconds maximum, 5-minute maximum, 10-minute maximum) - Illuminated Approach - Turn headlamps on with Remote Keyless Entry Unlock, Off or 30, 60 or 90 seconds - Display units in English or Metric - Compass Variance Setting 1 through 15 - Calibrate Compass Yes/No Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Page 9748 Driver/Vehicle Information Display: Testing and Inspection ELECTRONIC VEHICLE INFORMATION CENTER CAUTION: Do not place any external magnets, such as magnetic roof mount antennas, in the vicinity of the compass. Do not place any electronic devices (cell phones, laptop computers, PDAs, portable DVD players, etc), on or near the instrument panel as the Remote Compass Module (RCM) performance may be effected. Do not use magnetic tools when servicing the RCM. The Electronic Vehicle Information Center (EVIC) data is obtained from several components on the Controller Area Network (CAN) and Local Interface Network (LIN) Data Bus circuits. The EVIC will not function properly if the bus messages from any of these components is not received. If no EVIC data is displayed or the display indicates dashes "- -", check the CAN Data Bus circuit communications, the Instrument Cluster functions, the Remote Compass Module (RCM) and the Totally Integrated Power Module (TIPM). The use of a scan tool and the proper diagnostic procedures information are recommended for further testing of the EVIC, the RCM, the CAN Data Bus and Local Interface Network (LIN) Data Bus circuits. Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Adjustments > Compass Calibration Driver/Vehicle Information Display: Adjustments Compass Calibration COMPASS CALIBRATION CAUTION: Do not place any external magnets, such as magnetic roof mount antennas, in the vicinity of the compass. Do not place any electronic devices (cell phones, laptop computers, PDA's, portable DVD players, etc), on or near the instrument panel as the Remote Compass Module (RCM) performance may be effected. Do not use magnetic tools when servicing the RCM. The electronic compass unit features a continuous self-calibrating feature. This feature automatically updates the compass calibration as the vehicle is driven. This allows the compass unit to compensate for small changes in the residual magnetism that the vehicle may acquire during normal use. If the compass readings appear to be erratic or the Electronic Vehicle Information Center (EVIC) displays "CAL", perform the following calibration procedure. Also, any time a new RCM is installed, it must be calibrated using this procedure. Calibrate the compass manually as follows: NOTE: Do not attempt to calibrate the compass near large metal objects such as other vehicles, large buildings, or bridges; or, near overhead or underground power lines. 1. Start the engine but leave the vehicle in "PARK". 2. Continue to depress and release the STEP button (28) until the "Personal Settings" menu is displayed. 3. Once in the "Personal Settings" menu depress and release the STEP button (28) several times until "Calibrate Compass (Yes)" is displayed. 4. A long (longer than two seconds) STEP button press will place the compass in calibration mode. The "Cal" indicator will change from flashing to on continuously in the EVIC display (29) to indicate that the compass is now in the calibration mode and that the vehicle can now be driven to calibrate. (A short STEP button press from the "Calibrate Compass (Yes)" screen will exit the EVIC Customer Programmable features, and return it to its normal operating mode). 5. To complete the compass calibration, drive the vehicle in one or more complete 360 degree circles under 5 mph (8 km/h) in an area free of large metal objects such as other vehicles, large buildings, or bridges; or, near overhead or underground power lines, until the "CAL" indicator turns off. The compass will now function normally. NOTE: If the compass display indicates an inaccurate compass heading or the display is locked up, the RCM may be inoperative or the vehicle may need to be demagnetized. Perform the Compass Demagnetizing Procedure prior to performing any system diagnosis. NOTE: If the compass display indicates dashes "- -" the RCM may be inoperative or the vehicle may need to be demagnetized. Perform the Compass Demagnetizing Procedure prior to performing any system diagnosis. NOTE: If the "CAL" message remains in the display or if the compass heading is inaccurate following the calibration procedure and there are no internal compass faults, either there is excessive magnetism near the compass, or the unit is inoperative. Repeat the calibration procedure at least one more time prior to performing any system diagnosis. NOTE: If the wrong direction is still indicated in the compass display, the area selected for calibration may be too close to a strong magnetic field. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Adjustments > Compass Calibration > Page 9751 Repeat the calibration procedure in another location. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Adjustments > Compass Calibration > Page 9752 Driver/Vehicle Information Display: Adjustments Compass Variance Adjustment COMPASS VARIANCE ADJUSTMENT Compass variance, also known as magnetic declination, is the difference in angle between magnetic north and geographic north. In some geographic locations, the difference between magnetic and geographic north is great enough to cause the compass to give inaccurate readings. To optimize compass accuracy, the compass variance should be properly set according to the compass variance map zone for the region that the vehicle is in. To set the compass variance: 1. Using the Variance Settings map, find your geographic location and note the zone number. 2. Turn the ignition switch to the On position. 3. Continue to depress and release the STEP button (28) until the "Personal Settings" menu is displayed. 4. Once in the "Personal Settings" menu depress and release the STEP button (28) several times until "Compass Variance" is displayed. The "Compass Variance" message and the current variance zone number will be displayed. The default variance zone is 8. NOTE: During programming, the Zone value will wrap around from Zone 15 to Zone 1. 5. To change the zone, press and hold (longer than two seconds) the STEP button to increment the variance one step. Repeat as necessary, with individual long (longer than two seconds) STEP button presses for each increment, until the desired variance is achieved. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Adjustments > Compass Calibration > Page 9753 6. To exit the Variance Programming, press the STEP button with a short (less than one second) button press. 7. Confirm that the correct directions are now indicated by the compass. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Adjustments > Page 9754 Driver/Vehicle Information Display: Service and Repair COMPASS DEMAGNETIZING A degaussing tool (Special Tool 6029) is used to demagnetize, or degauss, the roof panel above the overhead console. Equivalent units must be rated as continuous duty for 110/115 volts and 60 Hz. They must also have a field strength of over 350 gauss at 7 millimeters (0.25 inch) beyond the tip of the probe. To demagnetize the roof panel proceed as follows: 1. Be certain that the ignition switch is in the Off position, before you begin the demagnetizing procedure. 2. Place a piece of paper approximately 22 by 28 centimeters (8.5 by 11 inches), oriented on the vehicle lengthwise from front to rear, on the center line of the roof at the windshield header. The purpose of the paper is to protect the roof panel from scratches, and to define the area to be demagnetized. 3. Connect the degaussing tool to an electrical outlet, while keeping the tool at least 61 centimeters (2 feet) away from the compass unit. 4. Slowly approach the center line of the roof panel at the windshield header, with the degaussing tool connected. 5. Contact the roof panel with the plastic coated tip of the degaussing tool. Be sure that the template is in place to avoid scratching the roof panel. Using a slow, back-and-forth sweeping motion, and allowing 13 millimeters (0.50 inch) between passes, move the tool at least 11 centimeters (4 inches) to each side of the roof center line, and 28 centimeters (11 inches) back from the windshield header. 6. With the degaussing tool still energized, slowly back it away from the roof panel. When the tip of the tool is at least 61 centimeters (2 feet) from the roof panel, disconnect the tool. 7. Calibrate the compass and adjust the compass variance. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Adjustments > Page 9755 Driver/Vehicle Information Display: Tools and Equipment ELECTRONIC VEHICLE INFORMATION CENTER DEGAUSSING TOOL 6029 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Filler Cap Warning Indicator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap Warning Indicator: > 14-001-06 > Jan > 06 > Fuel System - MIL ON/DTC P0457 Set Fuel Filler Cap Warning Indicator: Customer Interest Fuel System - MIL ON/DTC P0457 Set NUMBER: 14-001-06 GROUP: 14 - Fuel System DATE: January 21, 2006 SUBJECT: Loose Fuel Cap Message or MIL Illumination for Diagnostic Trouble Code P0457 EVAP System - Loose Fuel Cap MODELS: 2005 - 2006 (ND) Dakota 2005 - 2006 (CS) Pacifica 2006 (DR/DH) Ram Truck 2005 - 2006 (HB) Durango 2005 - 2006 (KJ) Liberty 2006 (LX) 300/Magnum/Charger 2006 (PT) PT Cruiser 2007 (PM) Caliber 2006 (RS) Town & Country/Caravan/Voyager 2006 (TJ) Wrangler 2005 - 2006 (WK) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. NOTE: Do not replace the gas cap if only DTC P0457 - Evap System - Loose Fuel Cap is present. DISCUSSION: Starting with the introduction of 2005 model year vehicles a new diagnostic trouble code (DTC) P0457 - Evap System - Loose Fuel Cap was introduced. Also added to some vehicles was an instrument cluster message in the odometer display or message center (EVIC) that alerts the driver that the gas cap is loose. The PCM monitors the fuel level for a "significant" change in either direction and remembers that this has recently occurred. A loose fuel cap DTC, cluster message or message center message matures when the check for the EVAP system large leak condition fails after the fuel level change event. If a leak of greater than 0.090" is observed after a fuel level change, a loose cap diagnostic single trip failure is stored and the cluster message or message center message is displayed even though a DTC may not yet be present. DTC P0457 - Evap System - Loose Fuel Cap is stored and the MIL illuminated after 2 cold start failures of the large leak diagnostic checks following a fuel change event. Only the passing of one of the 3 EVAP system diagnostic routines large leak, small leak or loose gas cap) by the PCM will validate that the cap is no longer loose and turn off the MIL light or message. For 2007 model vehicles DTC P0457 - Evap System - Loose Fuel Cap will be stored and the MIL illuminated after 3 cold starts. To temporarily clear the gas cap loose message from the odometer or message center press the reset button on the odometer or message center while the message is being displayed. This clears the message for the current key cycle only. NOTE: The above works for all vehicles except, 2005 - 2006 Grand Cherokee or Commander. For these, the scantool must be used) To clear the gas cap loose message from the odometer or message center ensure the gas cap is tight and let the vehicle run the small leak diagnostic Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Filler Cap Warning Indicator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap Warning Indicator: > 14-001-06 > Jan > 06 > Fuel System - MIL ON/DTC P0457 Set > Page 9764 routine. The small leak diagnostic routine will pass a sealed system after an 8 hour soak and a negative 3° C change in fuel temperature from the last key cycle. NOTE: A heated garage may effect the small leak diagnostic routine. To clear the gas cap loose message from the odometer or message center and matured DTC (MIL light) diagnose and repair the leak and then erase DTC's with the DRBIII(R)/StarSCAN(TM) scantool NOTE: The DRBIII(R)/StarSCAN(TM) scantool may be used to reset the Loose Cap message. Select the PCM Reset function on StarSCAN(TM) (version 6.05_SPI or higher) or the Clear PCM Batt Disconnect function on DRB III(R). Disconnecting and reconnecting the battery will also clear the message. If a gas cap loose message is displayed or DTC P0457 - Evap System - Loose Fuel Cap is set without P0455 - Evap System Large Leak then ensure the gas cap it tight, no further service action is required. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Filler Cap Warning Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap Warning Indicator: > 14-001-06 > Jan > 06 > Fuel System - MIL ON/DTC P0457 Set Fuel Filler Cap Warning Indicator: All Technical Service Bulletins Fuel System - MIL ON/DTC P0457 Set NUMBER: 14-001-06 GROUP: 14 - Fuel System DATE: January 21, 2006 SUBJECT: Loose Fuel Cap Message or MIL Illumination for Diagnostic Trouble Code P0457 EVAP System - Loose Fuel Cap MODELS: 2005 - 2006 (ND) Dakota 2005 - 2006 (CS) Pacifica 2006 (DR/DH) Ram Truck 2005 - 2006 (HB) Durango 2005 - 2006 (KJ) Liberty 2006 (LX) 300/Magnum/Charger 2006 (PT) PT Cruiser 2007 (PM) Caliber 2006 (RS) Town & Country/Caravan/Voyager 2006 (TJ) Wrangler 2005 - 2006 (WK) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. NOTE: Do not replace the gas cap if only DTC P0457 - Evap System - Loose Fuel Cap is present. DISCUSSION: Starting with the introduction of 2005 model year vehicles a new diagnostic trouble code (DTC) P0457 - Evap System - Loose Fuel Cap was introduced. Also added to some vehicles was an instrument cluster message in the odometer display or message center (EVIC) that alerts the driver that the gas cap is loose. The PCM monitors the fuel level for a "significant" change in either direction and remembers that this has recently occurred. A loose fuel cap DTC, cluster message or message center message matures when the check for the EVAP system large leak condition fails after the fuel level change event. If a leak of greater than 0.090" is observed after a fuel level change, a loose cap diagnostic single trip failure is stored and the cluster message or message center message is displayed even though a DTC may not yet be present. DTC P0457 - Evap System - Loose Fuel Cap is stored and the MIL illuminated after 2 cold start failures of the large leak diagnostic checks following a fuel change event. Only the passing of one of the 3 EVAP system diagnostic routines large leak, small leak or loose gas cap) by the PCM will validate that the cap is no longer loose and turn off the MIL light or message. For 2007 model vehicles DTC P0457 - Evap System - Loose Fuel Cap will be stored and the MIL illuminated after 3 cold starts. To temporarily clear the gas cap loose message from the odometer or message center press the reset button on the odometer or message center while the message is being displayed. This clears the message for the current key cycle only. NOTE: The above works for all vehicles except, 2005 - 2006 Grand Cherokee or Commander. For these, the scantool must be used) To clear the gas cap loose message from the odometer or message center ensure the gas cap is tight and let the vehicle run the small leak diagnostic Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Filler Cap Warning Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap Warning Indicator: > 14-001-06 > Jan > 06 > Fuel System - MIL ON/DTC P0457 Set > Page 9770 routine. The small leak diagnostic routine will pass a sealed system after an 8 hour soak and a negative 3° C change in fuel temperature from the last key cycle. NOTE: A heated garage may effect the small leak diagnostic routine. To clear the gas cap loose message from the odometer or message center and matured DTC (MIL light) diagnose and repair the leak and then erase DTC's with the DRBIII(R)/StarSCAN(TM) scantool NOTE: The DRBIII(R)/StarSCAN(TM) scantool may be used to reset the Loose Cap message. Select the PCM Reset function on StarSCAN(TM) (version 6.05_SPI or higher) or the Clear PCM Batt Disconnect function on DRB III(R). Disconnecting and reconnecting the battery will also clear the message. If a gas cap loose message is displayed or DTC P0457 - Evap System - Loose Fuel Cap is set without P0455 - Evap System Large Leak then ensure the gas cap it tight, no further service action is required. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: Provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9775 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9776 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9777 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9778 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9779 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9780 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9781 5. Release the Secondary Terminal Lock, if required (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9782 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9783 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9784 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9785 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9786 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9787 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9788 Fuel Gauge: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9789 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9790 STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9791 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator > Component Information > Service and Repair Maintenance Required Lamp/Indicator: Service and Repair DaimlerChrysler provides no information regarding a Maintenance Required Lamp/Indicator for this vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair DaimlerChrysler provides no information regarding an Oil Change Reminder Lamp for this vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Component ID: 341 Component : SWITCH-ENGINE OIL PRESSURE Connector: Name : SWITCH-ENGINE OIL PRESSURE Color : LT. GREEN # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 EOP SIGNAL G6 20VT/GY 2-Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 9801 Component Location - 15 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 9802 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 9803 Oil Pressure Sender: Diagrams Component ID: 341 Component : SWITCH-ENGINE OIL PRESSURE Connector: Name : SWITCH-ENGINE OIL PRESSURE Color : LT. GREEN # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 EOP SIGNAL G6 20VT/GY 2-Component Location - 14 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 9804 Component Location - 15 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 9805 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Description and Operation > Description Oil Pressure Sender: Description and Operation Description DESCRIPTION The oil pressure switch is located on the left front side of the engine block. The oil pressure switch is a pressure sensitive switch that is activated by the engine's oil pressure (in the main oil gallery). The switch is a two terminal device (one terminal is provided to the wiring harness and the other terminal is the switch's metal housing that screws into the engine block). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Description and Operation > Description > Page 9808 Oil Pressure Sender: Description and Operation Operation OPERATION The oil pressure switch is normally "Closed." The switch changes from a "Closed" circuit to an "Open" circuit, on increasing pressure of 7 psig. The oil pressure switch changes from an "Open" circuit to a "Closed" circuit, on decreasing pressure, between 2 psig and 4 psig. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Service and Repair > Removal Oil Pressure Sender: Service and Repair Removal REMOVAL 1. Raise vehicle. 2. Disconnect electrical connector. 3. Remove oil pressure sensor using oil pressure socket C-4597 (1) and discard sensor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Service and Repair > Removal > Page 9811 Oil Pressure Sender: Service and Repair Installation INSTALLATION NOTE: If the oil pressure sensor is removed, it must be replaced with a new sensor. CAUTION: The oil pressure sensor has tapered threads, over tightening could crack the engine block. 1. Install oil pressure sensor using oil pressure socket C-4597 (1) and tighten to 8 Nm (71 in. lbs.). 2. Connect electrical connector. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Component ID: 348 Component : SWITCH-PARKING BRAKE Connector: Name : SWITCH-PARKING BRAKE Color : NATURAL # of pins : 1 Pin Description Circuit 1 PARK BRAKE SWITCH SENSE B25 20DG/WT Component Location - 35 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 9815 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 9816 Parking Brake Warning Switch: Diagrams Component ID: 348 Component : SWITCH-PARKING BRAKE Connector: Name : SWITCH-PARKING BRAKE Color : NATURAL # of pins : 1 Pin Description Circuit 1 PARK BRAKE SWITCH SENSE B25 20DG/WT Component Location - 35 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 9817 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Description and Operation Seat Belt Reminder Lamp: Description and Operation FASTEN SEAT BELTS To test the fasten seat belts function, turn the ignition switch to the ON position with the driver's seat belt unbuckled and fully retracted. The seat belt warning lamp should light for four to eight seconds and the tone should sound three to five times. If the lamp does not light, check the connection at the seat belt retractor. Replace as necessary. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Component ID: 348 Component : SWITCH-PARKING BRAKE Connector: Name : SWITCH-PARKING BRAKE Color : NATURAL # of pins : 1 Pin Description Circuit 1 PARK BRAKE SWITCH SENSE B25 20DG/WT Component Location - 35 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 9825 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 9826 Parking Brake Warning Switch: Diagrams Component ID: 348 Component : SWITCH-PARKING BRAKE Connector: Name : SWITCH-PARKING BRAKE Color : NATURAL # of pins : 1 Pin Description Circuit 1 PARK BRAKE SWITCH SENSE B25 20DG/WT Component Location - 35 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 9827 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front Tire Pressure Monitor Receiver / Transponder: Locations Transponder-Tire Pressure-Left Front Component ID: 361 Component : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Connector: Name : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Color : YELLOW # of pins : 6 Qualifier : (TIRE PRESSURE MONITOR) Pin Description Circuit 1 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 GROUND Z904 20BK/OR 4 GROUND Z904 20BK/OR 5-6-- Component Location - 13 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 9833 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 9834 Tire Pressure Monitor Receiver / Transponder: Locations Transponder-Tire Pressure-Left Rear Component ID: 362 Component : TRANSPONDER-TIRE PRESSURE-LEFT REAR Connector: Name : TRANSPONDER-TIRE PRESSURE-LEFT REAR Color : BLACK # of pins : 6 Qualifier : (TIRE PRESSURE MONITOR) Pin Description Circuit 1 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 GROUND Z904 20BK/OR 4-5-6-- Component Location - 58 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 9835 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 9836 Tire Pressure Monitor Receiver / Transponder: Locations Transponder-Tire Pressure-Right Rear Component ID: 363 Component : TRANSPONDER-TIRE PRESSURE-RIGHT REAR Connector: Name : TRANSPONDER-TIRE PRESSURE-RIGHT REAR Color : BLACK # of pins : 6 Qualifier : (TIRE PRESSURE MONITOR) Pin Description Circuit 1 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 GROUND Z965 20BK/GY 4-5-6 GROUND Z965 20BK/GY Component Location - 59 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 9837 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front Tire Pressure Monitor Receiver / Transponder: Diagrams Transponder-Tire Pressure-Left Front Component ID: 361 Component : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Connector: Name : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Color : YELLOW # of pins : 6 Qualifier : (TIRE PRESSURE MONITOR) Pin Description Circuit 1 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 GROUND Z904 20BK/OR 4 GROUND Z904 20BK/OR 5-6-- Component Location - 13 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 9840 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 9841 Tire Pressure Monitor Receiver / Transponder: Diagrams Transponder-Tire Pressure-Left Rear Component ID: 362 Component : TRANSPONDER-TIRE PRESSURE-LEFT REAR Connector: Name : TRANSPONDER-TIRE PRESSURE-LEFT REAR Color : BLACK # of pins : 6 Qualifier : (TIRE PRESSURE MONITOR) Pin Description Circuit 1 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 GROUND Z904 20BK/OR 4-5-6-- Component Location - 58 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 9842 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 9843 Tire Pressure Monitor Receiver / Transponder: Diagrams Transponder-Tire Pressure-Right Rear Component ID: 363 Component : TRANSPONDER-TIRE PRESSURE-RIGHT REAR Connector: Name : TRANSPONDER-TIRE PRESSURE-RIGHT REAR Color : BLACK # of pins : 6 Qualifier : (TIRE PRESSURE MONITOR) Pin Description Circuit 1 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY 3 GROUND Z965 20BK/GY 4-5-6 GROUND Z965 20BK/GY Component Location - 59 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 9844 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Description Tire Pressure Monitor Receiver / Transponder: Description and Operation Description DESCRIPTION A transponder, sometimes referred to as a trigger module, is located in three of the four wheel wells (behind the wheelhouse splash shields) of a vehicle equipped with Premium TPM. These transponders are used to provide the Wireless Control Module (WCM), commonly referred to as the Sentry Key Remote Entry Module (SKREEM), with the location of the tire pressure sensors on the vehicle. A fourth transponder is not necessary in the remaining wheel well due to the process-of-elimination theory. Once the system knows the location of the first three sensors it assumes the location of the fourth tire pressure sensor. On this vehicle, there is a transponder located in the left front, left rear, and right rear wheelhouse. There is not a transponder located in the right front wheelhouse. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Description > Page 9847 Tire Pressure Monitor Receiver / Transponder: Description and Operation Operation OPERATION On vehicles equipped with the premium TPM system, the Wireless Control Module (WCM), commonly referred to as the Sentry Key Remote Entry Module (SKREEM), uses transponders (trigger modules) located in three of the four wheel wells on the vehicle to provide it with the location of the tire pressure sensors on the vehicle. Like the base system, the WCM receives RF signals from all four rotating wheel speed sensors. When the WCM needs to know which sensor is located at a particular location on the vehicle, it directs the transponder at that location to send out a low frequency signal to excite the nearby sensor. The WCM then receives that excited signal and knows where that sensor is located. This auto-locating process only happens in the first 10 minutes of any WCM cycle while traveling at speeds above 20 mph (32 km/h). (The auto-locating process will start again only if the vehicle has been shut off for approximately 20 minutes or longer). Once the WCM has performed this to the three locations that have transponders, it uses the process-of-elimination theory to know that the fourth sensor ID signal is coming from. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Removal Tire Pressure Monitor Receiver / Transponder: Service and Repair Removal Front FRONT 1. Remove the wheelhouse splash shield at the transponder requiring service. 2. Disconnect the wiring harness connector (2) at the transponder (1). 3. Remove the mounting nuts (3), then remove the transponder (1). Rear REAR 1. Remove the wheelhouse splash shield at the transponder requiring service. 2. Disconnect the wiring harness connector (3) at the transponder (1). 3. Remove the mounting nuts (2), then remove the transponder (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Removal > Page 9850 Tire Pressure Monitor Receiver / Transponder: Service and Repair Installation Front FRONT 1. Position the transponder (1) and install the mounting nuts (3). 2. Connect the wiring harness connector (2) to the transponder (1). 3. Install the wheelhouse splash shield and all components removed to access it. 4. Perform the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests Rear REAR 1. Position the transponder (1) and install the mounting nuts (2). 2. Connect the wiring harness connector (3) to the transponder (1). 3. Install the rear wheelhouse splash shield and all components removed to access it. 4. Perform the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service Precautions Tire Pressure Sensor: Service Precautions CAUTION CAUTION: The use of tire sealants is strictly prohibited for vehicles equipped with the Tire Pressure Monitoring system. Tire sealants can clog tire pressure sensors. CAUTION: Any time a sensor is to be installed in a wheel, it is necessary to install a new sensor-to-wheel seal, metal washer and valve stem nut, to ensure air tight sealing. CAUTION: Tire pressure sensor valve stem caps and cores are specially designed for the sensors. Due to risk of corrosion, do not use a standard valve stem cap or core in a tire pressure sensor in place of the original equipment style sensor cap and core. CAUTION: When installing the valve core, be sure to tighten the core to specifications. Overtightening by a little as three or four inch pounds can damage the sensor. CAUTION: Do not attempt to install a tire pressure sensor in an aftermarket wheel. Use tire pressure sensors in original style factory wheels only. If aftermarket wheels are installed, and therefore do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. NOTE: TPM thresholds have been established for the original tire size equipped on the vehicle. Use original size tires only to maintain system accuracy. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Description and Operation > Description Tire Pressure Sensor: Description and Operation Description DESCRIPTION On vehicles equipped with Tire Pressure Monitoring (TPM), one tire pressure sensor (6) is mounted to each wheel (5) in place of the traditional tire valve stem. Each sensor has an internal battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the sensor must be replaced. The TPM system operates on a 315 MHz radio frequency. The 315 MHz sensors can be easily identified by a white outline oval (black center) insignia (3) on the sensor body. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Description and Operation > Description > Page 9856 The Export TPM system operates on a 433 MHz radio frequency. The 433 MHz sensors can be easily identified by either a solid white oval insignia (3) on the body or... ... a solid white oval insignia (3) with 433 printed in the center. The sensors are identical except for the oval insignia. The 433 MHz sensors can either have a black or grey sensor body. CAUTION: Although 315 MHz and 433 MHz sensors are identical in size and shape, they are not interchangeable. Always make sure the correct sensor is being used. NOTE: Sensors may be identified by valve stem cap color. From the factory, 315 MHz sensors have a gray valve stem cap while 433 MHz sensors have a black valve stem cap. Otherwise, once mounted inside a tire and wheel assembly you are not able to visually tell the difference between a 315 MHz and 433 MHz sensor. At that point, the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool may be used to identify the sensor frequency or the tire can be dismounted allowing visual inspection of the sensor body. The TPM sensors are designed for original style factory wheels. It is not recommended to install a tire pressure sensor in an aftermarket wheel (This could cause sealing and system performance issues). Do not attempt to install a tire pressure sensor in an aftermarket wheel. If aftermarket wheels are installed and do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Description and Operation > Description > Page 9857 The serviceable components of the tire pressure sensor are: - Sensor-To-Wheel Seal (2) and Metal Washer (1) - Valve Stem Cap (4) - Valve Stem Core - Valve Stem Nut (with pressed-in washer) (3) NOTE: Any time a sensor is installed on a wheel, a new Sensor-To-Wheel Seal (2), Metal Washer (1) and Valve Stem Nut (3) must be installed to ensure air tight sealing. A service kit is available. The valve stem caps and cores are specifically designed for the tire pressure monitoring sensors. Although similar to standard valve stem caps and cores, they are different. The valve stem cap has a special seal inside to keep moisture and corrosion out. The valve stem core has a special nickel coating to protect from corrosion. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Description and Operation > Description > Page 9858 Tire Pressure Sensor: Description and Operation Operation OPERATION The battery operated tire pressure sensor is both a transmitter and a receiver. The TPM sensor can be forced to transmit by using a special tool such as a TPM-RKE Analyzer, or from a transponder. The TPM-RKE Analyzer has the ability to change the sensor's operating mode to PARK MODE and to help diagnose a faulty TPM sensor. Using a TPM-RKE Analyzer can take up to a minute to force a transmission from a sensor. The TPM sensor can be in one of the following operating modes: - SLEEP MODE - This is the operating mode of a new TPM sensor. If placed on the vehicle as a road tire, the sensor will transmit once every 20 seconds when the vehicle is driven at speeds over 15 mph (24 km/h). Driving the vehicle continuously at this speed for more then 4 minutes will change the sensor state to DRIVE MODE. Stopping the vehicle for 20 minutes will change the sensor state to PARK MODE. If the vehicle is not moving, the sensor will only transmit on a pressure change greater then 1 psi (6.9 kPa). - PARK MODE - This is the correct operating mode when the vehicle is not moving. The sensor will transmit once every 13 hours to update the WCM, or will transmit on a 1 psi (6.9 kPa) delta change. The sensors will internally take a measurement of the tire pressure every minute to determine a change in tire pressure. - 30 BLOCK MODE - If the vehicle has been stopped for more then 20 minutes, or if the sensor's operating mode was forced to PARK MODE using a TPM-RKE Analyzer, the sensor's operating mode will transition from PARK MODE to 30 BLOCK MODE once the vehicle is driven over 15 mph. In this mode, the sensor will transmit once every 15 seconds when the vehicle is driven at speeds over 15 mph (24 km/h) for the first 30 transmissions. After about 8 minutes of continuous driving above 15 mph (24 km/h), the sensor's mode will change to DRIVE MODE. - DRIVE MODE - In this mode, the sensor will transmit once every minute when the vehicle is driven at speeds over 15 mph (24 km/h). At any time the vehicle speed drops below 15 mph, the sensor will not transmit. The sensor mode will still be in drive mode when the sensor reaches speeds over 15 mph (24 km/h), unless the vehicle has been stationary for more then 20 minutes. Each sensor's (transmitter) broadcast is uniquely coded so that the wireless control module (WCM) can monitor the state of each of the sensors on the four rotating road wheels. The WCM can automatically learn and store the sensor's ID while driving "within 10 minutes continuously above 15 mph (24 Km/h)" after a sensor has been replaced. The vehicle must be stationary for more then 20 minutes in order to initiate the learning sequence. The WCM can also learn the sensor's ID using the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool following the procedure listed in the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Removal Tire Pressure Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Remove wheel mounting nuts (3), then tire and wheel assembly (1). CAUTION: The cap used on this valve stem contains an O-ring seal to prevent contamination and moisture from entering the valve stem. Retain this valve stem cap for reuse. Do not substitute a regular valve stem cap in its place. CAUTION: The valve stem used on this vehicle is made of aluminum and the core is nickel plated brass. The original valve stem core must be reinstalled and not substituted with a valve stem core made of a different material. This is required to prevent corrosion in the valve stem caused by the different metals. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Removal > Page 9861 3. Dismount tire from wheel following tire changer manufacturers instructions while paying special attention to the following to avoid damaging the pressure sensor: a. When breaking the tire bead loose from the wheel rim, avoid using the Bead Breaker in the area of the sensor. That includes both front and rear beads of the tire. b. When preparing to dismount the tire from the wheel, carefully insert the mounting/dismounting tool at the valve stem ± 10°, then proceed to dismount the tire from the wheel. Use this process on both the upper and lower tire beads. 4. Remove sensor nut (3) retaining sensor to wheel. While removing nut, hold pressure against rear of metal valve stem to keep valve stem from pushing rearward, damaging antenna strap. 5. Remove sensor (1) from wheel (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Removal > Page 9862 Tire Pressure Sensor: Service and Repair Installation INSTALLATION NOTE: Before reinstalling an existing tire pressure sensor, replace seal (2) and metal washer (1) at base of sensor valve stem (6) to ensure proper sealing. 1. Wipe area clean around sensor/valve stem mounting hole in wheel (5). Make sure surface of wheel is not damaged. CAUTION: To avoid damaging sensor antenna strap (1), hold pressure against rear of metal valve stem (2) while sensor is inserted through wheel mounting hole and nut is installed. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Removal > Page 9863 2. Insert sensor (1) through wheel (2) as shown keeping pressure against rear of metal valve stem (See Arrow). Potted side of sensor is to be positioned toward wheel. Do not attempt to mount sensor otherwise, damage may occur. 3. Install sensor nut (with pressed-in washer) (3) by hand. NOTE: Before tightening sensor nut, push downward on sensor housing (2) in an attempt to make it flush with interior contour of wheel (1). 4. While holding sensor in position, tighten sensor nut to 8 Nm (71 in. lbs.). CAUTION: Over-torquing the sensor nut by as little as 12 Nm (106 in. lbs.) may result in sensor separation from the valve stem. Under this condition, the sensor may still function. However, the condition should be corrected immediately. 5. Mount tire on wheel following tire changer manufacturers instructions, paying special attention to the following to avoid damaging tire pressure sensor: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Removal > Page 9864 a. Rotating Wheel Tire Changers - Once the wheel is mounted to the changer, position the sensor valve stem (2) approximately 210° from the head of the changer (located at 1) in a clockwise direction before rotating the wheel (also in a clockwise direction) to mount the tire. Use this procedure on both the upper and lower tire beads. b. Rotating Tool Tire Changers - Position the wheel on the changer so that the sensor valve stem (1) is located approximately 210° clockwise from the installation end of the mounting/dismounting tool (2) once the tool is mounted for tire installation. Make sure the sensor is clear of the lower bead breaker area (3) to avoid damaging the sensor when the breaker rises. Rotate the tool (2) in a counterclockwise direction to mount the tire. Use this procedure on both the upper and lower tire beads. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Removal > Page 9865 6. Adjust air pressure to that listed on Tire Inflation Pressure Label (Placard) provided with vehicle (applied to driver's side B-pillar). Make sure original style and color valve stem cap is securely installed to keep moisture out of sensor. 7. Install tire and wheel assembly (1) on vehicle. Tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 8. Lower vehicle. 9. Perform one of the following to make the system learn the new sensor ID. a. Use the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool to program the WCM/SKREEM with the tire pressure sensor ID. This is part of the TPM Diagnostic Verification Test. b. Once the vehicle has remained stationary for more than 20 minutes, drive vehicle for a minimum of 10 minutes while maintaining a continuous speed above 15 mph (24 km/h). During this time, the system will learn the new sensor ID. This is part of the TPM Diagnostic Verification Test. NOTE: If a sensor cannot be trained, refer to appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations Component ID: 338 Component : SWITCH-BACKUP LAMP Connector: Name : SWITCH-BACKUP LAMP Color : LT. GRAY # of pins : 2 Qualifier : (DIESEL) Pin Description Circuit 1 GROUND Z967 18BK/VT 2 BACKUP LAMP SWITCH SIGNAL T22 20YL/VT Component Location - 12 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 9871 Connector: Name : SWITCH-BACKUP LAMP Color : GRAY # of pins : 2 Qualifier : (GAS MTX) A GROUND Z967 18BK/VT B BACKUP LAMP SWITCH SIGNAL T22 20YL/VT Component Location - 12 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 9872 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 9873 Backup Lamp Switch: Diagrams Component ID: 338 Component : SWITCH-BACKUP LAMP Connector: Name : SWITCH-BACKUP LAMP Color : LT. GRAY # of pins : 2 Qualifier : (DIESEL) Pin Description Circuit 1 GROUND Z967 18BK/VT 2 BACKUP LAMP SWITCH SIGNAL T22 20YL/VT Component Location - 12 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 9874 Connector: Name : SWITCH-BACKUP LAMP Color : GRAY # of pins : 2 Qualifier : (GAS MTX) A GROUND Z967 18BK/VT B BACKUP LAMP SWITCH SIGNAL T22 20YL/VT Component Location - 12 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 9875 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Service and Repair > BG6 Manual Transaxle Backup Lamp Switch: Service and Repair BG6 Manual Transaxle Removal REMOVAL 1. Disconnect battery negative cable. 2. Raise vehicle on hoist. 3. Disconnect backup lamp switch connector. 4. Remove backup lamp switch (1). Installation INSTALLATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Service and Repair > BG6 Manual Transaxle > Page 9878 1. Install the backup lamp switch (1) with a new washer and tighten to 40 Nm (29 ft. lbs.). 2. Connect backup lamp switch connector. 3. Lower vehicle. 4. Connect battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Service and Repair > BG6 Manual Transaxle > Page 9879 Backup Lamp Switch: Service and Repair T355 Manual Transaxle Removal REMOVAL 1. Lift vehicle on hoist. 2. From bottom side of vehicle, disconnect back-up lamp switch connector (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Service and Repair > BG6 Manual Transaxle > Page 9880 3. Unscrew switch (2) from transaxle. Installation INSTALLATION Install back-up lamp switch (2). Teflon tape or equivalent must be used on switch threads. Tighten switch to 24 Nm (18 ft. lbs.). CAUTION: Do not overtighten switch. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Service and Repair > BG6 Manual Transaxle > Page 9881 1. Connect back-up lamp switch connector (2). 2. Lower vehicle. 3. Verify back-up lamp operation. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Service and Repair > Removal Brake Light Bulb: Service and Repair Removal BULBS There are a total of four possible bulbs in the tail lamp unit: - Back-Up Lamp (4) - Park/Brake Lamp (1) - Rear Fog Lamp (5) - Export Only - Turn Signal (3) 1. Remove the tail lamp unit. NOTE: It is not necessary to completely remove the tail lamp unit. Once loosened from quarter panel, there should be enough room to service any of the bulbs. 2. Disconnect the electrical connector. 3. Remove bulb socket from tail lamp unit by twisting a quarter turn counterclockwise. 4. Pull socket straight out of tail lamp unit. 5. Pull bulb from socket. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Service and Repair > Removal > Page 9887 Brake Light Bulb: Service and Repair Installation BULBS There are a total of four possible bulbs in the tail lamp unit: - Back-Up Lamp (4) - Park/Brake Lamp (1) - Rear Fog Lamp (5) - Export Only - Turn Signal (3) 1. Push bulb into the bulb socket. 2. Install bulb socket into tail lamp assembly. Rotate the socket clockwise until fully seated. 3. Install the tail lamp unit. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations Component ID: 358 Component : SWITCH-STOP LAMP Connector: Name : SWITCH-STOP LAMP Color : BLACK # of pins : 6 Pin Description Circuit 1 FUSED B(+) A924 20DG/WT 2 STOP LAMP SWITCH OUTPUT L53 20DG/WT 3 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 4 BRAKE SIGNAL 2 B16 20LB/DG 5 GROUND Z967 18BK/VT 6 BRAKE SIGNAL 1 B15 20DG/WT Component Location - 44 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 9891 Component Location - 47 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 9892 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 9893 Brake Light Switch: Diagrams Component ID: 358 Component : SWITCH-STOP LAMP Connector: Name : SWITCH-STOP LAMP Color : BLACK # of pins : 6 Pin Description Circuit 1 FUSED B(+) A924 20DG/WT 2 STOP LAMP SWITCH OUTPUT L53 20DG/WT 3 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 4 BRAKE SIGNAL 2 B16 20LB/DG 5 GROUND Z967 18BK/VT 6 BRAKE SIGNAL 1 B15 20DG/WT Component Location - 44 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 9894 Component Location - 47 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 9895 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Description Brake Light Switch: Description and Operation Description DESCRIPTION The stop lamp switch (3) is located under the instrument panel, at the brake pedal (2). It has three internal switches controlling various functions of the vehicle. It's main function is to control operation of the vehicle's brake lamps. Other functions include speed control deactivation, brake sense for the antilock brake system and brake sense for the brake transmission shift interlock. CAUTION: The switch can only be adjusted once. That is during initial installation of the switch. If the switch is not adjusted properly or has been removed for some service, a new switch must be installed and adjusted. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Description > Page 9898 Brake Light Switch: Description and Operation Operation OPERATION When the brake pedal is pressed, the plunger on the outside of the stop lamp switch extends outward. This action opens or closes the contacts of the three switches inside the stop lamp switch. With the brake pedal pressed down (plunger extended), the switch for terminals 1 and 2 is closed completing the circuit. The switch for terminals 3 and 4 is open and so is the switch for 5 and 6. When the brake pedal is released (plunger pushed in), the three switches assume the opposite positions. The switch for terminals 1 and 2 is now open while the other two switches are now closed, completing their circuits. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 9899 Brake Light Switch: Testing and Inspection STOP LAMP SWITCH NOTE: Before proceeding with this diagnostic test, verify the adjustment lever on the back of the switch is in the adjusted position. If the lever is in the non-adjusted (diagonal) position it may have never been adjusted. If the electrical circuit has been tested and the stop lamp switch is suspected of being damaged or inoperative, it can be tested using the following method. 1. Remove the switch from the vehicle. 2. With the switch in the released position (plunger extended), use an ohmmeter to test each of the three internal switches as shown. You should achieve the results as listed in the figure. 3. Gently push the plunger on the stop lamp switch in until it stops. 4. With the switch in this depressed position (plunger pushed in), use an ohmmeter to test each of the three internal switches as shown. You should achieve the results as listed in the figure. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 9900 If you do not achieve the results as listed in both figures, the switch must be replaced. If the switch is found to be operating properly, it may be misadjusted. Do not reinstall the switch, replace it. CAUTION: The switch can only be adjusted once. That is during initial installation of the switch. If the switch is not adjusted properly or has been removed for any reason, a new switch must be installed and adjusted. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Removal Brake Light Switch: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable from its post on the battery. 2. If equipped, remove the silencer pad below the steering column. 3. Disconnect the wiring harness connector (4) at the switch (3). 4. Remove the stop lamp switch (2) from the brake pedal bracket (1) by rotating the switch in a counterclockwise direction approximately 30 degrees, then pulling the switch rearward. 5. Discard the stop lamp switch. It must not be reused. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Removal > Page 9903 Brake Light Switch: Service and Repair Installation INSTALLATION CAUTION: Do not reuse the original stop lamp switch. The switch can only be adjusted once. That is during initial installation of the switch. If the switch is not adjusted properly or has been removed for some service, a new switch must be installed and adjusted. 1. Obtain a NEW stop lamp switch. The adjustment lever on the NEW switch should be at a 45° angle from the wiring connector. If the adjustment lever is parallel with the wiring connector, the switch has been pre-set and must be scrapped. DO NOT ATTEMPT TO RESET (OR RE-ADJUST) THE STOP LAMP SWITCH. 2. Mount and adjust the NEW brake lamp switch (2) using the following steps: a. Install the switch in its bracket by aligning the index tab on the switch with the notch in the brake pedal bracket (1). b. When the switch body is fully seated in its bracket, rotate the switch clockwise approximately 30° to lock the switch into place. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Removal > Page 9904 c. With the brake pedal in the fully released position, move the adjustment lever on the brake lamp switch from the 45° angled non-adjusted position, clockwise as shown, until it is parallel with the wiring connector. The brake lamp switch is now properly adjusted to the vehicle. 3. Connect the wiring harness connector (4) to the switch (3). 4. If equipped, install the silencer pad below the steering column. 5. Reconnect the battery negative terminal. 6. Check the stop lamps to verify they are operating properly and not staying on when the pedal is in the released position. 7. Road test the vehicle to ensure proper operation of the brakes (including ABS) and speed control (if equipped). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Locations Cargo Lamp: Locations Component ID: 116 Component : LAMP-CARGO Connector: Name : LAMP-CARGO Color : BLACK # of pins : 3 Pin Description Circuit 1-2 COURTESY LAMPS DRIVER M24 20YL/WT 3 GROUND Z936 20BK/LB Component Location - 43 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Locations > Page 9908 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Locations > Page 9909 Cargo Lamp: Diagrams Component ID: 116 Component : LAMP-CARGO Connector: Name : LAMP-CARGO Color : BLACK # of pins : 3 Pin Description Circuit 1-2 COURTESY LAMPS DRIVER M24 20YL/WT 3 GROUND Z936 20BK/LB Component Location - 43 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Locations > Page 9910 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Description and Operation > Description Cargo Lamp: Description and Operation Description DESCRIPTION An optional dual-purpose cargo lamp (1) includes a removable and rechargeable flashlight (5). The flashlight is encased within a molded plastic housing, which is secured within the cargo lamp housing by two tabs on the end opposite the clear flashlight lens and a push-push type latch mechanism. The cargo lamp remains functional with or without the flashlight installed in the lamp housing. The flashlight is powered by a rechargeable and replaceable lithium battery. A momentary switch on the flashlight electronic circuit board is actuated by a plastic push button (3) located on the side of the flashlight housing. When the flashlight is turned ON it illuminates two clear Light Emitting Diode (LED) units (2) to create a wide and bright light beam. A red LED unit (4) on the side of the flashlight housing behind the push button illuminates as the battery becomes discharged to indicate that the unit requires recharging. The incandescent cargo lamp bulb, the cargo lamp lens, the flashlight battery and the flashlight unit are each available for separate service replacement. If any other component of the lamp or the flashlight are damaged or ineffective, the complete cargo lamp or flashlight unit must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Description and Operation > Description > Page 9913 Cargo Lamp: Description and Operation Operation OPERATION The rechargeable lithium battery within the flashlight automatically recharges while the flashlight is nested in its receptacle within the cargo lamp housing and the ignition switch is in the ON or START positions. The flashlight has a pair of electrical contacts that mate with contacts within the cargo lamp housing that provide a source of recharging current regardless of whether the cargo lamp is illuminated. The red Light Emitting Diode (LED) unit on the side of the flashlight behind the ON-OFF push button illuminates when the charge of the flashlight battery is becoming depleted. The flashlight is removed from the cargo lamp housing by pushing it momentarily upward at the depression marked PUSH on the flashlight, then releasing it and swinging it downward far enough to disengage two slots on the right end of the flashlight from two tabs within the cargo lamp housing. When the flashlight is removed from its receptacle in the cargo lamp housing, it can be used as an auxiliary light source in emergencies or other situations. The flashlight is turned ON or OFF by momentarily depressing and releasing the ON-OFF push button on the side of the flashlight housing. Reverse the removal procedure to restore the flashlight to the cargo lamp housing and to recharge the flashlight battery. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Service and Repair > Procedures Cargo Lamp: Procedures FLASHLIGHT BATTERY REPLACEMENT 1. Insert a small screwdriver or another suitable tool into each of the two notches (2) between the upper (1) and lower (3) case halves of the flashlight and use a twisting action to separate the case. 2. Remove the lower case (4) from the upper case (3) and set it aside. 3. Lightly lift the latch tab (2) at the back of the upper case and slide the battery (1) rearward far enough to remove it from the case. 4. Install the new battery by sliding it between the latch tab and the case until it is engaged by the latch tab. The battery must be installed with the positive (+) terminal oriented toward the upper case (3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Service and Repair > Procedures > Page 9916 Cargo Lamp: Removal and Replacement Bulb - With Flashlight Feature BULB - WITH FLASHLIGHT FEATURE NOTE: There are two types of cargo lamps available in this vehicle; one with and one without a removable flashlight feature. 1. Disconnect and isolate the battery negative cable. 2. Remove the flashlight from the cargo lamp housing (2). 3. Pull downward on the straight edge of the lens (1) to unsnap it from the lamp housing, then disengage the curved edge of the lens from the housing. 4. Carefully unsnap the bulb (3) from the two bulb holders within the cargo lamp housing. Bulb - Without Flashlight Feature BULB - WITHOUT FLASHLIGHT FEATURE NOTE: There are two types of cargo lamps available in this vehicle; one with and one without a removable flashlight feature. 1. Disconnect and isolate the battery negative cable. 2. Insert the tip of a small flat-bladed screwdriver into the notch on one side of the cargo lamp between the lens (4) and the lamp housing (1). 3. Gently pry the notched edge of the lens downward until it unsnaps from the housing. 4. Swing the notched end of the lens downward far enough to access the bulb (3). 5. Carefully unsnap the bulb from the two bulb holders within the cargo lamp housing. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Service and Repair > Procedures > Page 9917 Lamp - With Flashlight Feature LAMP - WITH FLASHLIGHT FEATURE NOTE: There are two types of cargo lamps available in this vehicle; one with and one without a removable flashlight feature. 1. Disconnect and isolate the battery negative cable. 2. Remove the flashlight from the cargo lamp housing (1). 3. Remove the trim from the inside of both upper D-pillars. 4. Remove the push pin fastener (4) adjacent to each side of the cargo lamp that secures the headliner (5) to the upper D-pillar reinforcement (2). 5. Carefully pull down the rear edge of the headliner from the upper liftgate opening header (3) far enough to insert a trim stick or another suitable wide flat-bladed tool between the back of the lamp housing and the header. 6. Gently pry the lamp housing (1) downward far enough to disengage the snap clip retainer (3) from the upper liftgate opening header. 7. Reach between the headliner and the header to access and depress the two spring tabs (2) far enough to disengage the forward edge of the lamp housing from the mounting hole in the headliner. 8. Slide the lamp housing forward far enough to disengage the two fixed retainers (5) from the rear edge of the headliner mounting hole. 9. Pull the lamp downward from the headliner far enough to access and disconnect the headliner wire harness connector from the connector receptacle (4) on the back of the lamp housing. 10. Remove the cargo lamp from the vehicle. Lamp - Without Flashlight Feature Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Service and Repair > Procedures > Page 9918 LAMP - WITHOUT FLASHLIGHT FEATURE NOTE: There are two types of cargo lamps available in this vehicle; one with and one without a removable flashlight feature. 1. Disconnect and isolate the battery negative cable. 2. Insert the tip of a small flat bladed screwdriver into the notch (5) between the lens (2) and the housing (1) on one side of the cargo lamp unit. 3. Gently pry the end of the lens downward until it unsnaps from the housing. 4. Swing the lens downward until it is perpendicular to the housing. 5. Pull the lens hinge/retainer end (3) of the housing downward slightly from the headliner, then slide the exposed end of the housing away from the mounting hole far enough to disengage the fixed retainer (4) on the notched end from the headliner. 6. Pull the lamp away from the headliner mounting hole far enough to access and disconnect the wire harness connector from the connector receptacle on the back of the lamp housing. 7. Remove the lamp from the vehicle. Lamp - With Flashlight Feature LAMP - WITH FLASHLIGHT FEATURE NOTE: There are two types of cargo lamps available in this vehicle; one with and one without a removable flashlight feature. 1. Position the cargo lamp (1) with the flashlight removed close enough to the headliner to reconnect the headliner wire harness connector to the connector receptacle (4) on the back of the lamp. 2. Engage the two fixed retainers (5) into the rear edge of the headliner mounting hole. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Service and Repair > Procedures > Page 9919 3. Slide the lamp housing rearward far enough to obtain clearance between the front edge of the lamp housing and the front of the headliner mounting hole for the lamp. 4. Depress the two spring tabs (2) far enough to push the forward edge of the lamp housing up into the mounting hole in the headliner, then release the spring tabs to engage the back of the headliner substrate. 5. Align the snap clip retainer (3) with the hole in the upper liftgate opening header. 6. Press firmly and evenly upward on the center of the flashlight receptacle in the cargo lamp housing (1) until the snap clip retainer on the back of the lamp snaps into place in the hole in the upper liftgate opening header (3). 7. Reinstall the push pin fastener (4) adjacent to each side of the cargo lamp that secures the headliner (5) to the upper D-pillar reinforcement (2). 8. Reinstall the trim onto the inside of both upper D-pillars. 9. Reinstall the flashlight into the cargo lamp housing. 10. Reconnect the battery negative cable. Lamp - Without Flashlight Feature LAMP - WITHOUT FLASHLIGHT FEATURE NOTE: There are two types of cargo lamps available in this vehicle; one with and one without a removable flashlight feature. 1. Position the cargo lamp unit (1) to the mounting hole in the headliner. 2. Reconnect the wire harness connector to the connector receptacle on the back of the lamp housing. 3. Insert the fixed retainer (4) on the notched end (5) of the lamp housing up into one side of the mounting hole in the headliner. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Service and Repair > Procedures > Page 9920 4. Slide the notched end of the housing into the mounting hole far enough to engage the lens hinge/retainer (3) into the opposite side of the hole in the headliner. 5. Gently and evenly press the lens hinge/retainer end of the lamp into the mounting hole until the bezel of the lamp housing is flush with the headliner. 6. Swing the notched end of the lamp lens (2) into position against the lamp housing, then press on the lens firmly and evenly until it snaps into the housing. 7. Reconnect the battery negative cable. Bulb - With Flashlight Feature BULB - WITH FLASHLIGHT FEATURE CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. NOTE: There are two types of cargo lamps available in this vehicle; one with and one without a removable flashlight feature. 1. Align the ends of the bulb (3) with the two bulb holders within the cargo lamp housing (2). 2. Carefully press the bulb firmly and evenly into the bulb holders until it snaps into place. 3. Position the curved edge of the lens (1) into position against the housing, then press upward on the straight edge of the lens firmly and evenly until it snaps into the housing. 4. Reinstall the flashlight into the cargo lamp housing. 5. Reconnect the battery negative cable. Bulb - Without Flashlight Feature BULB - WITHOUT FLASHLIGHT FEATURE CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. NOTE: There are two types of cargo lamps available in this vehicle; one with and one without a removable flashlight feature. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Service and Repair > Procedures > Page 9921 1. Align the ends of the bulb (3) with the two bulb holders within the cargo lamp housing (1). 2. Carefully press the bulb firmly and evenly into the bulb holders until it snaps into place. 3. Swing the notched end of the lens (4) up into position against the housing, then press upward on the lens firmly and evenly until it snaps into the housing. 4. Reconnect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Center Mounted Brake Lamp Bulb > Component Information > Service and Repair > Removal Center Mounted Brake Lamp Bulb: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the rear spoiler. 3. With spoiler on bench, remove the two screws to the CHMSL. 4. Remove CHMSL from spoiler. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Center Mounted Brake Lamp Bulb > Component Information > Service and Repair > Removal > Page 9927 Center Mounted Brake Lamp Bulb: Service and Repair Installation INSTALLATION 1. Place CHMSL onto rear spoiler. 2. Install the two mounting screws to the CHMSL. 3. Install the rear spoiler. 4. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Technical Service Bulletins > Lighting - Information On Exterior Lamp Lens Fogging Cornering Lamp: Technical Service Bulletins Lighting - Information On Exterior Lamp Lens Fogging NUMBER: 23-035-07 GROUP: Body DATE: August 08, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-041-06, DATED SEPTEMBER 27, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Exterior Lamp - Lens Fogging MODELS: 2006 - 2008 (CS) Pacifica 2006 - 2008 (DC/DM) Ram Truck - Cab & Chassis (3500/4500/5500) 2006 - 2008 (DR/DH/D1) Ram Truck - Pick-up (1500/2500/3500) 2006 - 2008 (HB/HG) Durango/Aspen 2007 - 2008 (JK) Wrangler 2006 (JR) Stratus/Sebring 2006 - 2007 (JR27) Sebring Convertible 2007 - 2008 (JS) Sebring/Avenger 2008 (JS27) Sebring Convertible 2007 - 2008 (KA) Nitro 2006 - 2007 (KJ) Liberty/Cherokee 2008 (KK) Liberty/Cherokee 2006 - 2008 (LX/LE) 300/Magnum/Charger 2007 - 2008 (MK49) Compass 2007 - 2008 (MK74) Patriot 2006 - 2008 (ND) Dakota 2007 - 2008 (PM) Caliber 2006 - 2008 (PT) PT Cruiser 2006 - 2007 (RS/RG) Town & Country/Caravan/Voyager 2008 (RT) Town & Country/Caravan/Voyager 2006-2008 (WK/WH) Grand Cherokee 2006 - 2008 (XK/XH) Commander DISCUSSION: Some customers may report that on occasion, vehicle exterior lamp assemblies are fogged with a light layer of condensation on the inside of the lenses. This may be reported after the lamps have been turned on and brought up to operating temperature, turned off, and then rapidly cooled by cold water (such as rain, or the water from a car wash). Lens fogging can also occur under certain atmospheric conditions after a vehicle has been parked outside overnight (i.e., a warm humid day followed by clear cool night). This will usually clear as atmospheric conditions change to allow the condensation to change back into a vapor. Turning the lamps on will usually accelerate this process. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Technical Service Bulletins > Lighting - Information On Exterior Lamp Lens Fogging > Page 9932 A lamp that has large amounts of water droplets visible on most internal surfaces indicates a problem with the lamp sealing that has allowed water to enter the lamp. In this instance, the customer is likely to report that moisture in the lamp is always present and never disappears. A lamp that exhibits internal moisture permanently should be replaced. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Bulb > Component Information > Service and Repair > Removal Courtesy Lamp Bulb: Service and Repair Removal BULB 1. Insert a trim stick between the lamp bezel (4) and courtesy/reading lamp lens (3) on the left side of the courtesy/reading lamp at (1). 2. Carefully swing lamp lens (3) toward the right side of the vehicle so that the tab (2) on the lens can come out of the lamp unit (4). 3. Remove bulb (3) from lamp unit (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Bulb > Component Information > Service and Repair > Removal > Page 9938 Courtesy Lamp Bulb: Service and Repair Installation BULB 1. Position bulb (3) in holder and firmly press into place. NOTE: When installing the lens (5), make sure that the tab on the lens (4) is inserted on the right side of the courtesy/reading lamp unit first. 2. Once the right side tab (2) is in the headliner, roll up the left side of the lens (3) until it snaps into place at (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Description and Operation > Description Daytime Running Lamp Relay: Description and Operation Description DESCRIPTION Vehicles built for use in Canada, and also available as an option on vehicles for sale in the U.S., are equipped with a Daytime Running Lamp (DRL) system. All the exterior lighting messages come from Steering Control Module (SCM) or left multi-function switch on Local Interconnect Network (LIN) data bus and goes to the Cab Compartment Node (CCN), then the CCN sends out a Controller Area Network (CAN) data bus message to the Totally Integrated Power Module (TIPM) for each lighting function according to the request from left multi-function switch. Then the TIPM will turn ON/OFF the requested output. The DRL function is controlled by TIPM. Daytime running lamps are High beam lamps at lower intensity. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Description and Operation > Description > Page 9944 Daytime Running Lamp Relay: Description and Operation Operation OPERATION The Canadian cluster provides steady illumination of the front turn signal when the ignition switch is in the ON position. The Daytime Running Lamp (DRL) function may be inhibited by activating the turn signals, the hazard flashers, the headlamp switch, or park brake. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service and Repair > Removal Dome Lamp Bulb: Service and Repair Removal BULB 1. On lower line vehicles, there will be two overhead lamps located at (1 and 2). (1) is the Cargo Lamp, and (2) is the Dome Lamp. 2. Insert a trim stick or equivalent between the lamp unit (3) and the lens (1) at this position (2). 3. Carefully remove the lamp lens (1). 4. Remove lamp from lamp unit. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service and Repair > Removal > Page 9950 Dome Lamp Bulb: Service and Repair Installation BULB 1. Push lamp in lamp unit (3) and snap into place. 2. Position lens (1) on lamp unit (3) and snap into place. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information > Service and Repair > Removal Fog/Driving Lamp Bulb: Service and Repair Removal BULB 1. Disconnect and isolate the battery negative cable. 2. Reach up through the lower fascia (3) cutout. 3. Disconnect the fog lamp connector (1). 4. Twist the bulb (2) counterclockwise to remove from lamp unit. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information > Service and Repair > Removal > Page 9956 Fog/Driving Lamp Bulb: Service and Repair Installation BULB 1. Reach up through the lower fascia (3) cutout. 2. Place bulb (2) into lamp unit and twist clockwise until stops, approximately 90 degrees. 3. Connect the fog lamp bulb electrical connector (1). 4. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Application and ID Hazard Warning Flasher: Application and ID PLEASE NOTE: The Flasher Function for this vehicle is provided by the Totally Integrated Power Module (TIPM). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Description and Operation > Description Hazard Warning Switch: Description and Operation Description DESCRIPTION The hazard switch is located in the Accessory Switch Bank Module (ASBM) just below the heater a/c controls, in the instrument panel center stack. This switch is the control for the hazard warning lighting. The only visible component of the switch is the control push button that is located just to the left of the Passenger Airbag Disabled Light (PADL) indicator. On BUX models, the hazard switch is located to the left of the Headlamp Leveling Switch, in the ASBM. The hazard switch cannot be adjusted or repaired. If the switch is ineffective or damaged, the entire ASBM must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Description and Operation > Description > Page 9965 Hazard Warning Switch: Description and Operation Operation OPERATION The hazard switch features a push-push type latching push button. When the push button is in its latched (lowered) position the switch contacts are open, and when the push button is in its unlatched (raised) position the switch contacts are closed. The hazard switch receives a ground on one terminal and provides a ground signal output to the Totally Integrated Power Module (TIPM) ) whenever the switch contacts are closed. The TIPM responds to this input by controlling a battery voltage output and the flash rate for each of the right and left turn signal lamps, then sends an electronic hazard switch status message over the Controller Area Network (CAN) data bus to the Electromechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) to control the illumination and flash rate of the right and left turn signal indicators, as well as to control the click rate of an electromechanical relay soldered onto the EMIC electronic circuit board that emulates the sound emitted by a conventional hazard warning flasher. The hazard switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair > Removal Headlamp Bulb: Service and Repair Removal BULBS 1. Disconnect and isolate the battery negative cable. 2. Hoist vehicle. 3. Working in the appropriate wheel well, loosen up the front of the splash shield, but don't fully remove it. 4. Looking up through the front wheel well, locate the bulb (1) in which needs replacing. The headlamp bulb is the inboard bulb and the park/turn signal bulb is the outboard bulb. 5. Disconnect the bulb electrical connector (2 or 3). NOTE: EXPORT ONLY - If removing/replacing the headlamp bulb on export vehicles there is a rubber cover over the rear of the lamp housing that must be removed to access the bulb. Then a spring clip must be removed and the bulb pulled straight rearward. 6. Grasp the bulb (1), twist 1/4 turn counterclockwise and pull straight out of front lamp unit. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair > Removal > Page 9971 Headlamp Bulb: Service and Repair Installation BULBS 1. Reaching up through wheel well, install the headlamp or park/turn signal bulb (1) in the front lamp unit, locking it into place by twisting a 1/4 turn clockwise. NOTE: EXPORT ONLY - If installing/replacing the headlamp bulb on export vehicles push the bulb straight in unit and then install the spring clip. Install the rubber cover over the rear of the lamp housing, over the headlamp bulb. 2. Connect the bulb electrical connector (2 or 3). 3. Install the front of the splash shield (6) removed to gain access to the front lamp unit bulbs. 4. Lower vehicle from hoist. 5. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Service and Repair > Removal Horn Relay: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove cover from Totally Integrated Power Module (TIPM). 3. Using special tool C-4817 (1), grip the relay (2) by the sides and pull upward with an even effort. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Service and Repair > Removal > Page 9977 Horn Relay: Service and Repair Installation INSTALLATION 1. Align relay (2) with Totally Integrated Power Module (TIPM) and press into position. 2. Install cover to TIPM. 3. Connect battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations Horn Switch: Locations Component ID: 344 Component : SWITCH-HORN Connector: Name : SWITCH-HORN Color : BLACK # of pins : 2 Pin Description Circuit 1 HORN SWITCH SENSE X3 20DB 2 RADIO CONTROL RETURN Y13 20BK Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations > Page 9981 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations > Page 9982 Horn Switch: Diagrams Component ID: 344 Component : SWITCH-HORN Connector: Name : SWITCH-HORN Color : BLACK # of pins : 2 Pin Description Circuit 1 HORN SWITCH SENSE X3 20DB 2 RADIO CONTROL RETURN Y13 20BK Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations > Page 9983 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Description and Operation > Description Horn Switch: Description and Operation Description DESCRIPTION WARNING: On vehicles equipped with an airbag, refer to restraint systems for warnings and cautions before servicing the horn switch. The horn switch is mounted inside the driver airbag. The horn switch has three contacts that are grounded when the driver airbag is depressed. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Description and Operation > Description > Page 9986 Horn Switch: Description and Operation Operation OPERATION When the Driver Airbag Cover is pressed, the horn switch makes contact to ground. The ground signal is carried to the horn relay and the horn sounds. The horn switch grounds to the airbag housing. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Service and Repair > Removal Horn Switch: Service and Repair Removal REMOVAL WARNING: On vehicles equipped with an airbag, refer to restraint systems for warnings and cautions before servicing the horn switch. 1. Disconnect and isolate the battery negative cable. 2. Remove the driver airbag. 3. Disconnect the connector from the clockspring. 4. Remove the three mounting fasteners. 5. Remove the horn switch. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Service and Repair > Removal > Page 9989 Horn Switch: Service and Repair Installation INSTALLATION 1. Install the horn switch. 2. Install the three mounting fasteners. 3. Connect the electrical connector to the clockspring. 4. Install the driver airbag. 5. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > License Plate Bulb > Component Information > Service and Repair > Removal License Plate Bulb: Service and Repair Removal BULB 1. Remove the license plate lamp unit from the liftgate. 2. Pull bulb from socket. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > License Plate Bulb > Component Information > Service and Repair > Removal > Page 9995 License Plate Bulb: Service and Repair Installation BULB 1. Install bulb into socket. 2. Install the license plate lamp unit into the liftgate. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information > Service and Repair > Removal Marker Lamp Bulb: Service and Repair Removal BULBS 1. Disconnect and isolate the battery negative cable. 2. Hoist vehicle. 3. Working in the appropriate wheel well, loosen up the front of the splash shield, but don't fully remove it. 4. Looking up through the front wheel well, locate the bulb (1) in which needs replacing. The headlamp bulb is the inboard bulb and the park/turn signal bulb is the outboard bulb. 5. Disconnect the bulb electrical connector (2 or 3). NOTE: EXPORT ONLY - If removing/replacing the headlamp bulb on export vehicles there is a rubber cover over the rear of the lamp housing that must be removed to access the bulb. Then a spring clip must be removed and the bulb pulled straight rearward. 6. Grasp the bulb (1), twist 1/4 turn counterclockwise and pull straight out of front lamp unit. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information > Service and Repair > Removal > Page 10001 Marker Lamp Bulb: Service and Repair Installation BULBS 1. Reaching up through wheel well, install the headlamp or park/turn signal bulb (1) in the front lamp unit, locking it into place by twisting a 1/4 turn clockwise. NOTE: EXPORT ONLY - If installing/replacing the headlamp bulb on export vehicles push the bulb straight in unit and then install the spring clip. Install the rubber cover over the rear of the lamp housing, over the headlamp bulb. 2. Connect the bulb electrical connector (2 or 3). 3. Install the front of the splash shield (6) removed to gain access to the front lamp unit bulbs. 4. Lower vehicle from hoist. 5. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Technical Service Bulletins > Lighting - Information On Exterior Lamp Lens Fogging Parking Lamp: Technical Service Bulletins Lighting - Information On Exterior Lamp Lens Fogging NUMBER: 23-035-07 GROUP: Body DATE: August 08, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-041-06, DATED SEPTEMBER 27, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Exterior Lamp - Lens Fogging MODELS: 2006 - 2008 (CS) Pacifica 2006 - 2008 (DC/DM) Ram Truck - Cab & Chassis (3500/4500/5500) 2006 - 2008 (DR/DH/D1) Ram Truck - Pick-up (1500/2500/3500) 2006 - 2008 (HB/HG) Durango/Aspen 2007 - 2008 (JK) Wrangler 2006 (JR) Stratus/Sebring 2006 - 2007 (JR27) Sebring Convertible 2007 - 2008 (JS) Sebring/Avenger 2008 (JS27) Sebring Convertible 2007 - 2008 (KA) Nitro 2006 - 2007 (KJ) Liberty/Cherokee 2008 (KK) Liberty/Cherokee 2006 - 2008 (LX/LE) 300/Magnum/Charger 2007 - 2008 (MK49) Compass 2007 - 2008 (MK74) Patriot 2006 - 2008 (ND) Dakota 2007 - 2008 (PM) Caliber 2006 - 2008 (PT) PT Cruiser 2006 - 2007 (RS/RG) Town & Country/Caravan/Voyager 2008 (RT) Town & Country/Caravan/Voyager 2006-2008 (WK/WH) Grand Cherokee 2006 - 2008 (XK/XH) Commander DISCUSSION: Some customers may report that on occasion, vehicle exterior lamp assemblies are fogged with a light layer of condensation on the inside of the lenses. This may be reported after the lamps have been turned on and brought up to operating temperature, turned off, and then rapidly cooled by cold water (such as rain, or the water from a car wash). Lens fogging can also occur under certain atmospheric conditions after a vehicle has been parked outside overnight (i.e., a warm humid day followed by clear cool night). This will usually clear as atmospheric conditions change to allow the condensation to change back into a vapor. Turning the lamps on will usually accelerate this process. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Technical Service Bulletins > Lighting - Information On Exterior Lamp Lens Fogging > Page 10006 A lamp that has large amounts of water droplets visible on most internal surfaces indicates a problem with the lamp sealing that has allowed water to enter the lamp. In this instance, the customer is likely to report that moisture in the lamp is always present and never disappears. A lamp that exhibits internal moisture permanently should be replaced. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Locations > Lamp-Park/Turn-Left Front Parking Lamp: Locations Lamp-Park/Turn-Left Front Component ID: 125 Component : LAMP-PARK/TURN-LEFT FRONT Connector: Name : LAMP-PARK/TURN-LEFT FRONT Color : BLACK # of pins : 3 Qualifier : (EXCEPT EXPORT) Pin Description Circuit 1 GROUND Z904 20BK/LG 2 HEADLAMP SWITCH OUTPUT L7 20WT/VT 3 LEFT TURN SIGNAL L61 20WT/RD Component Location - 1 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Locations > Lamp-Park/Turn-Left Front > Page 10009 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Locations > Lamp-Park/Turn-Left Front > Page 10010 Parking Lamp: Locations Lamp-Park/Turn-Right Front Component ID: 126 Component : LAMP-PARK/TURN-RIGHT FRONT Connector: Name : LAMP-PARK/TURN-RIGHT FRONT Color : BLACK # of pins : 3 Qualifier : (EXCEPT EXPORT) Pin Description Circuit 1 GROUND Z908 20BK/PK 2 HEADLAMP SWITCH OUTPUT L70 20WT/GY 3 RIGHT TURN SIGNAL L60 20WT/TN Component Location - 1 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Locations > Lamp-Park/Turn-Left Front > Page 10011 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions Parking Lamp: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: Provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10014 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10015 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10016 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10017 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10018 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10019 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10020 5. Release the Secondary Terminal Lock, if required (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10021 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10022 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10023 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10024 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10025 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10026 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10027 Parking Lamp: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10028 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10029 STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10030 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10031 Parking Lamp: Connector Views Lamp-Park/Turn-Left Front Component ID: 125 Component : LAMP-PARK/TURN-LEFT FRONT Connector: Name : LAMP-PARK/TURN-LEFT FRONT Color : BLACK # of pins : 3 Qualifier : (EXCEPT EXPORT) Pin Description Circuit 1 GROUND Z904 20BK/LG 2 HEADLAMP SWITCH OUTPUT L7 20WT/VT 3 LEFT TURN SIGNAL L61 20WT/RD Component Location - 1 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10032 Lamp-Park/Turn-Right Front Component ID: 126 Component : LAMP-PARK/TURN-RIGHT FRONT Connector: Name : LAMP-PARK/TURN-RIGHT FRONT Color : BLACK # of pins : 3 Qualifier : (EXCEPT EXPORT) Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10033 Pin Description Circuit 1 GROUND Z908 20BK/PK 2 HEADLAMP SWITCH OUTPUT L70 20WT/GY 3 RIGHT TURN SIGNAL L60 20WT/TN Component Location - 1 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Description and Operation > Description Daytime Running Lamp Relay: Description and Operation Description DESCRIPTION Vehicles built for use in Canada, and also available as an option on vehicles for sale in the U.S., are equipped with a Daytime Running Lamp (DRL) system. All the exterior lighting messages come from Steering Control Module (SCM) or left multi-function switch on Local Interconnect Network (LIN) data bus and goes to the Cab Compartment Node (CCN), then the CCN sends out a Controller Area Network (CAN) data bus message to the Totally Integrated Power Module (TIPM) for each lighting function according to the request from left multi-function switch. Then the TIPM will turn ON/OFF the requested output. The DRL function is controlled by TIPM. Daytime running lamps are High beam lamps at lower intensity. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Description and Operation > Description > Page 10039 Daytime Running Lamp Relay: Description and Operation Operation OPERATION The Canadian cluster provides steady illumination of the front turn signal when the ignition switch is in the ON position. The Daytime Running Lamp (DRL) function may be inhibited by activating the turn signals, the hazard flashers, the headlamp switch, or park brake. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Service and Repair > Removal Horn Relay: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove cover from Totally Integrated Power Module (TIPM). 3. Using special tool C-4817 (1), grip the relay (2) by the sides and pull upward with an even effort. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Service and Repair > Removal > Page 10044 Horn Relay: Service and Repair Installation INSTALLATION 1. Align relay (2) with Totally Integrated Power Module (TIPM) and press into position. 2. Install cover to TIPM. 3. Connect battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations Component ID: 338 Component : SWITCH-BACKUP LAMP Connector: Name : SWITCH-BACKUP LAMP Color : LT. GRAY # of pins : 2 Qualifier : (DIESEL) Pin Description Circuit 1 GROUND Z967 18BK/VT 2 BACKUP LAMP SWITCH SIGNAL T22 20YL/VT Component Location - 12 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 10049 Connector: Name : SWITCH-BACKUP LAMP Color : GRAY # of pins : 2 Qualifier : (GAS MTX) A GROUND Z967 18BK/VT B BACKUP LAMP SWITCH SIGNAL T22 20YL/VT Component Location - 12 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 10050 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 10051 Backup Lamp Switch: Diagrams Component ID: 338 Component : SWITCH-BACKUP LAMP Connector: Name : SWITCH-BACKUP LAMP Color : LT. GRAY # of pins : 2 Qualifier : (DIESEL) Pin Description Circuit 1 GROUND Z967 18BK/VT 2 BACKUP LAMP SWITCH SIGNAL T22 20YL/VT Component Location - 12 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 10052 Connector: Name : SWITCH-BACKUP LAMP Color : GRAY # of pins : 2 Qualifier : (GAS MTX) A GROUND Z967 18BK/VT B BACKUP LAMP SWITCH SIGNAL T22 20YL/VT Component Location - 12 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 10053 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > BG6 Manual Transaxle Backup Lamp Switch: Service and Repair BG6 Manual Transaxle Removal REMOVAL 1. Disconnect battery negative cable. 2. Raise vehicle on hoist. 3. Disconnect backup lamp switch connector. 4. Remove backup lamp switch (1). Installation INSTALLATION Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > BG6 Manual Transaxle > Page 10056 1. Install the backup lamp switch (1) with a new washer and tighten to 40 Nm (29 ft. lbs.). 2. Connect backup lamp switch connector. 3. Lower vehicle. 4. Connect battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > BG6 Manual Transaxle > Page 10057 Backup Lamp Switch: Service and Repair T355 Manual Transaxle Removal REMOVAL 1. Lift vehicle on hoist. 2. From bottom side of vehicle, disconnect back-up lamp switch connector (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > BG6 Manual Transaxle > Page 10058 3. Unscrew switch (2) from transaxle. Installation INSTALLATION Install back-up lamp switch (2). Teflon tape or equivalent must be used on switch threads. Tighten switch to 24 Nm (18 ft. lbs.). CAUTION: Do not overtighten switch. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > BG6 Manual Transaxle > Page 10059 1. Connect back-up lamp switch connector (2). 2. Lower vehicle. 3. Verify back-up lamp operation. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations Component ID: 358 Component : SWITCH-STOP LAMP Connector: Name : SWITCH-STOP LAMP Color : BLACK # of pins : 6 Pin Description Circuit 1 FUSED B(+) A924 20DG/WT 2 STOP LAMP SWITCH OUTPUT L53 20DG/WT 3 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 4 BRAKE SIGNAL 2 B16 20LB/DG 5 GROUND Z967 18BK/VT 6 BRAKE SIGNAL 1 B15 20DG/WT Component Location - 44 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 10063 Component Location - 47 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 10064 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 10065 Brake Light Switch: Diagrams Component ID: 358 Component : SWITCH-STOP LAMP Connector: Name : SWITCH-STOP LAMP Color : BLACK # of pins : 6 Pin Description Circuit 1 FUSED B(+) A924 20DG/WT 2 STOP LAMP SWITCH OUTPUT L53 20DG/WT 3 IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 4 BRAKE SIGNAL 2 B16 20LB/DG 5 GROUND Z967 18BK/VT 6 BRAKE SIGNAL 1 B15 20DG/WT Component Location - 44 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 10066 Component Location - 47 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 10067 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Description Brake Light Switch: Description and Operation Description DESCRIPTION The stop lamp switch (3) is located under the instrument panel, at the brake pedal (2). It has three internal switches controlling various functions of the vehicle. It's main function is to control operation of the vehicle's brake lamps. Other functions include speed control deactivation, brake sense for the antilock brake system and brake sense for the brake transmission shift interlock. CAUTION: The switch can only be adjusted once. That is during initial installation of the switch. If the switch is not adjusted properly or has been removed for some service, a new switch must be installed and adjusted. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Description > Page 10070 Brake Light Switch: Description and Operation Operation OPERATION When the brake pedal is pressed, the plunger on the outside of the stop lamp switch extends outward. This action opens or closes the contacts of the three switches inside the stop lamp switch. With the brake pedal pressed down (plunger extended), the switch for terminals 1 and 2 is closed completing the circuit. The switch for terminals 3 and 4 is open and so is the switch for 5 and 6. When the brake pedal is released (plunger pushed in), the three switches assume the opposite positions. The switch for terminals 1 and 2 is now open while the other two switches are now closed, completing their circuits. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 10071 Brake Light Switch: Testing and Inspection STOP LAMP SWITCH NOTE: Before proceeding with this diagnostic test, verify the adjustment lever on the back of the switch is in the adjusted position. If the lever is in the non-adjusted (diagonal) position it may have never been adjusted. If the electrical circuit has been tested and the stop lamp switch is suspected of being damaged or inoperative, it can be tested using the following method. 1. Remove the switch from the vehicle. 2. With the switch in the released position (plunger extended), use an ohmmeter to test each of the three internal switches as shown. You should achieve the results as listed in the figure. 3. Gently push the plunger on the stop lamp switch in until it stops. 4. With the switch in this depressed position (plunger pushed in), use an ohmmeter to test each of the three internal switches as shown. You should achieve the results as listed in the figure. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 10072 If you do not achieve the results as listed in both figures, the switch must be replaced. If the switch is found to be operating properly, it may be misadjusted. Do not reinstall the switch, replace it. CAUTION: The switch can only be adjusted once. That is during initial installation of the switch. If the switch is not adjusted properly or has been removed for any reason, a new switch must be installed and adjusted. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Removal Brake Light Switch: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable from its post on the battery. 2. If equipped, remove the silencer pad below the steering column. 3. Disconnect the wiring harness connector (4) at the switch (3). 4. Remove the stop lamp switch (2) from the brake pedal bracket (1) by rotating the switch in a counterclockwise direction approximately 30 degrees, then pulling the switch rearward. 5. Discard the stop lamp switch. It must not be reused. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Removal > Page 10075 Brake Light Switch: Service and Repair Installation INSTALLATION CAUTION: Do not reuse the original stop lamp switch. The switch can only be adjusted once. That is during initial installation of the switch. If the switch is not adjusted properly or has been removed for some service, a new switch must be installed and adjusted. 1. Obtain a NEW stop lamp switch. The adjustment lever on the NEW switch should be at a 45° angle from the wiring connector. If the adjustment lever is parallel with the wiring connector, the switch has been pre-set and must be scrapped. DO NOT ATTEMPT TO RESET (OR RE-ADJUST) THE STOP LAMP SWITCH. 2. Mount and adjust the NEW brake lamp switch (2) using the following steps: a. Install the switch in its bracket by aligning the index tab on the switch with the notch in the brake pedal bracket (1). b. When the switch body is fully seated in its bracket, rotate the switch clockwise approximately 30° to lock the switch into place. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Removal > Page 10076 c. With the brake pedal in the fully released position, move the adjustment lever on the brake lamp switch from the 45° angled non-adjusted position, clockwise as shown, until it is parallel with the wiring connector. The brake lamp switch is now properly adjusted to the vehicle. 3. Connect the wiring harness connector (4) to the switch (3). 4. If equipped, install the silencer pad below the steering column. 5. Reconnect the battery negative terminal. 6. Check the stop lamps to verify they are operating properly and not staying on when the pedal is in the released position. 7. Road test the vehicle to ensure proper operation of the brakes (including ABS) and speed control (if equipped). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Description Combination Switch: Description and Operation Description DESCRIPTION The left (lighting) multi-function switch is located on the left side of the steering column, just below the steering wheel. This switch is the primary control for the interior and exterior lighting systems. The only visible components of the switch are the control stalk (2), control knob (1) and control sleeve (3) that extend through the steering column shrouds on the left side of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator are concealed beneath the shrouds. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Description > Page 10081 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Description > Page 10082 Combination Switch: Description and Operation Operation OPERATION The left (lighting) multi-function switch uses resistor multiplexing to control the many functions and features it provides using a minimal number of hard wired circuits. The switch then sends electronic switch status messages over the Local Interconnect Network (LIN) to the Cab Compartment Node (CCN) and then the CCN sends messages over the Controller Area Network (CAN) data bus to the Totally Integrated Power Module (TIPM) other electronic modules in the vehicle. For lighting and wiper function it sends the messages over the LIN bus to the CCN and the CCN puts them out on the CAN bus to the other modules. The left switch has the microprocessor for all communication to the TIPM. The SCCM is composed of a clockspring and left lighting switch and a right wiper switch. The TIPM, controls the lighting and wiper functions. The left multi-function switch can be diagnosed using LIN based diagnostic tools and methods. However, the most reliable, efficient and accurate means to diagnose this component requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. EXTERIOR LIGHTING Following are descriptions of how the left multi-function switch is operated to control the many exterior lighting functions and features it provides: - Front Fog Lamps - The optional front fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the front fog lamps to be selected while the headlamp On position is also selected, and will automatically move the control knob to the front fog lamps Off position when the control knob is rotated to deselect the headlamps. - Headlamps - The headlamps are requested when the left multi-function switch control knob is rotated to the headlamps on detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Headlamp Beam Selection - The headlamp beams are selected when the left multi-function switch control stalk is pushed forward. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. Each time the control stalk is actuated in this manner, the headlamp beams are toggled from the current selection to the opposite selection. - Headlamp Optical Horn - The headlamp optical horn is selected each time the left multi-function switch control stalk is pulled rearward to a momentary position just short of the beam selection detent position. The headlamp high beams will remain illuminated for as long as the control stalk is held in this momentary position and the previously selected beams will be restored when the control stalk is released. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Park Lamps - The headlamps are requested when the left multi-function switch control knob is rotated to the park lamps on detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Rear Fog Lamps - The optional rear fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position and then rotated to the rear fog lamps detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the rear fog lamps to be selected while the front fog lamps On position is also selected, and will automatically move the control knob to the rear fog lamp Off position when the control knob is pushed in to deselect the front fog lamps. - Turn Signal Control - The turn signals are requested when the left multi-function switch control stalk is moved downward (left signal) or upward (right signal). The control stalk has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary "lane change" position in each direction that provides turn signals only until the control stalk is released. When the control stalk is moved to a detent turn signal switch position, a cancel actuator extends toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring, rotates with the steering wheel and the cam lobes contact the cancel actuator when it is extended from the left multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the two turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the left turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral Off position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. INTERIOR LIGHTING Following are descriptions of the how the left multi-function switch is operated to control the many interior lighting functions and features it provides: - Interior Lamps Defeat - The interior lamps defeat feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps defeat detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Description > Page 10083 CAN data bus to the other electronic modules in the vehicle. - Interior Lamps On - The interior lamps on feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps On detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Panel Lamps Dimming - The panel lamps dimming function is active only when the left multi-function switch control knob is in any exterior lighting On position. With the exterior lighting On, the panel lamps dimming level is requested when the left multi-function switch control sleeve is rotated to any one of five minor detent positions. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Parade Mode - The parade or funeral mode is active only when the left multi-function switch control knob is in any exterior lighting On position. With the exterior lighting On, the parade mode is requested when the left multi-function switch control sleeve is rotated to the parade mode detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair > Removal Combination Switch: Service and Repair Removal REMOVAL NOTE: It is not necessary to remove the Steering Column Control Module (SCCM) from the steering column to replace the left multi-function switch (2). 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the system reserve capacitor to discharge before servicing any airbag or steering column components. 2. Remove both the upper and lower shrouds from the steering column. 3. Remove the one screw (2) that secures the left multi-function switch (3) on the right side of the clockspring (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair > Removal > Page 10086 4. Pull the switch (2) straight away from the clockspring (1) far enough to access the electrical connector (3) to disconnect it. 5. Disconnect the instrument panel wiring harness from the back of the left multi-function switch. 6. Remove the switch (2) from the clockspring (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair > Removal > Page 10087 Combination Switch: Service and Repair Installation INSTALLATION 1. Position the left multi-function switch in the slot in the back of the clockspring (1) and connect the switch connector (3). 2. Connect the instrument panel wiring harness connector to the back of the left multi-function switch. 3. Align switch (3) with the clockspring (1) and slide toward steering column. 4. Install the screw (2) that secures the switch (3) to the clockspring (1). 5. Install the upper and lower shrouds onto the steering column. 6. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Description and Operation > Description Hazard Warning Switch: Description and Operation Description DESCRIPTION The hazard switch is located in the Accessory Switch Bank Module (ASBM) just below the heater a/c controls, in the instrument panel center stack. This switch is the control for the hazard warning lighting. The only visible component of the switch is the control push button that is located just to the left of the Passenger Airbag Disabled Light (PADL) indicator. On BUX models, the hazard switch is located to the left of the Headlamp Leveling Switch, in the ASBM. The hazard switch cannot be adjusted or repaired. If the switch is ineffective or damaged, the entire ASBM must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Description and Operation > Description > Page 10092 Hazard Warning Switch: Description and Operation Operation OPERATION The hazard switch features a push-push type latching push button. When the push button is in its latched (lowered) position the switch contacts are open, and when the push button is in its unlatched (raised) position the switch contacts are closed. The hazard switch receives a ground on one terminal and provides a ground signal output to the Totally Integrated Power Module (TIPM) ) whenever the switch contacts are closed. The TIPM responds to this input by controlling a battery voltage output and the flash rate for each of the right and left turn signal lamps, then sends an electronic hazard switch status message over the Controller Area Network (CAN) data bus to the Electromechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) to control the illumination and flash rate of the right and left turn signal indicators, as well as to control the click rate of an electromechanical relay soldered onto the EMIC electronic circuit board that emulates the sound emitted by a conventional hazard warning flasher. The hazard switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations Horn Switch: Locations Component ID: 344 Component : SWITCH-HORN Connector: Name : SWITCH-HORN Color : BLACK # of pins : 2 Pin Description Circuit 1 HORN SWITCH SENSE X3 20DB 2 RADIO CONTROL RETURN Y13 20BK Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 10096 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 10097 Horn Switch: Diagrams Component ID: 344 Component : SWITCH-HORN Connector: Name : SWITCH-HORN Color : BLACK # of pins : 2 Pin Description Circuit 1 HORN SWITCH SENSE X3 20DB 2 RADIO CONTROL RETURN Y13 20BK Component Location - 34 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 10098 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Description and Operation > Description Horn Switch: Description and Operation Description DESCRIPTION WARNING: On vehicles equipped with an airbag, refer to restraint systems for warnings and cautions before servicing the horn switch. The horn switch is mounted inside the driver airbag. The horn switch has three contacts that are grounded when the driver airbag is depressed. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Description and Operation > Description > Page 10101 Horn Switch: Description and Operation Operation OPERATION When the Driver Airbag Cover is pressed, the horn switch makes contact to ground. The ground signal is carried to the horn relay and the horn sounds. The horn switch grounds to the airbag housing. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service and Repair > Removal Horn Switch: Service and Repair Removal REMOVAL WARNING: On vehicles equipped with an airbag, refer to restraint systems for warnings and cautions before servicing the horn switch. 1. Disconnect and isolate the battery negative cable. 2. Remove the driver airbag. 3. Disconnect the connector from the clockspring. 4. Remove the three mounting fasteners. 5. Remove the horn switch. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service and Repair > Removal > Page 10104 Horn Switch: Service and Repair Installation INSTALLATION 1. Install the horn switch. 2. Install the three mounting fasteners. 3. Connect the electrical connector to the clockspring. 4. Install the driver airbag. 5. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Light Bulb > Component Information > Service and Repair > Removal Tail Light Bulb: Service and Repair Removal BULBS There are a total of four possible bulbs in the tail lamp unit: - Back-Up Lamp (4) - Park/Brake Lamp (1) - Rear Fog Lamp (5) - Export Only - Turn Signal (3) 1. Remove the tail lamp unit. NOTE: It is not necessary to completely remove the tail lamp unit. Once loosened from quarter panel, there should be enough room to service any of the bulbs. 2. Disconnect the electrical connector. 3. Remove bulb socket from tail lamp unit by twisting a quarter turn counterclockwise. 4. Pull socket straight out of tail lamp unit. 5. Pull bulb from socket. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Light Bulb > Component Information > Service and Repair > Removal > Page 10110 Tail Light Bulb: Service and Repair Installation BULBS There are a total of four possible bulbs in the tail lamp unit: - Back-Up Lamp (4) - Park/Brake Lamp (1) - Rear Fog Lamp (5) - Export Only - Turn Signal (3) 1. Push bulb into the bulb socket. 2. Install bulb socket into tail lamp assembly. Rotate the socket clockwise until fully seated. 3. Install the tail lamp unit. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions Trailer Lamps: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: Provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10115 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10116 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10117 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10118 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10119 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10120 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10121 5. Release the Secondary Terminal Lock, if required (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10122 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10123 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10124 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10125 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10126 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10127 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10128 Trailer Lamps: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10129 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10130 STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10131 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Description and Operation > Description Combination Switch: Description and Operation Description DESCRIPTION The left (lighting) multi-function switch is located on the left side of the steering column, just below the steering wheel. This switch is the primary control for the interior and exterior lighting systems. The only visible components of the switch are the control stalk (2), control knob (1) and control sleeve (3) that extend through the steering column shrouds on the left side of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator are concealed beneath the shrouds. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Description and Operation > Description > Page 10137 ERROR: undefined OFFENDING COMMAND: ‘~ STACK: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Description and Operation > Description > Page 10138 Combination Switch: Description and Operation Operation OPERATION The left (lighting) multi-function switch uses resistor multiplexing to control the many functions and features it provides using a minimal number of hard wired circuits. The switch then sends electronic switch status messages over the Local Interconnect Network (LIN) to the Cab Compartment Node (CCN) and then the CCN sends messages over the Controller Area Network (CAN) data bus to the Totally Integrated Power Module (TIPM) other electronic modules in the vehicle. For lighting and wiper function it sends the messages over the LIN bus to the CCN and the CCN puts them out on the CAN bus to the other modules. The left switch has the microprocessor for all communication to the TIPM. The SCCM is composed of a clockspring and left lighting switch and a right wiper switch. The TIPM, controls the lighting and wiper functions. The left multi-function switch can be diagnosed using LIN based diagnostic tools and methods. However, the most reliable, efficient and accurate means to diagnose this component requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. EXTERIOR LIGHTING Following are descriptions of how the left multi-function switch is operated to control the many exterior lighting functions and features it provides: - Front Fog Lamps - The optional front fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the front fog lamps to be selected while the headlamp On position is also selected, and will automatically move the control knob to the front fog lamps Off position when the control knob is rotated to deselect the headlamps. - Headlamps - The headlamps are requested when the left multi-function switch control knob is rotated to the headlamps on detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Headlamp Beam Selection - The headlamp beams are selected when the left multi-function switch control stalk is pushed forward. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. Each time the control stalk is actuated in this manner, the headlamp beams are toggled from the current selection to the opposite selection. - Headlamp Optical Horn - The headlamp optical horn is selected each time the left multi-function switch control stalk is pulled rearward to a momentary position just short of the beam selection detent position. The headlamp high beams will remain illuminated for as long as the control stalk is held in this momentary position and the previously selected beams will be restored when the control stalk is released. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Park Lamps - The headlamps are requested when the left multi-function switch control knob is rotated to the park lamps on detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Rear Fog Lamps - The optional rear fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position and then rotated to the rear fog lamps detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the rear fog lamps to be selected while the front fog lamps On position is also selected, and will automatically move the control knob to the rear fog lamp Off position when the control knob is pushed in to deselect the front fog lamps. - Turn Signal Control - The turn signals are requested when the left multi-function switch control stalk is moved downward (left signal) or upward (right signal). The control stalk has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary "lane change" position in each direction that provides turn signals only until the control stalk is released. When the control stalk is moved to a detent turn signal switch position, a cancel actuator extends toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring, rotates with the steering wheel and the cam lobes contact the cancel actuator when it is extended from the left multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the two turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the left turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral Off position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. INTERIOR LIGHTING Following are descriptions of the how the left multi-function switch is operated to control the many interior lighting functions and features it provides: - Interior Lamps Defeat - The interior lamps defeat feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps defeat detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Description and Operation > Description > Page 10139 CAN data bus to the other electronic modules in the vehicle. - Interior Lamps On - The interior lamps on feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps On detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Panel Lamps Dimming - The panel lamps dimming function is active only when the left multi-function switch control knob is in any exterior lighting On position. With the exterior lighting On, the panel lamps dimming level is requested when the left multi-function switch control sleeve is rotated to any one of five minor detent positions. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Parade Mode - The parade or funeral mode is active only when the left multi-function switch control knob is in any exterior lighting On position. With the exterior lighting On, the parade mode is requested when the left multi-function switch control sleeve is rotated to the parade mode detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Service and Repair > Removal Combination Switch: Service and Repair Removal REMOVAL NOTE: It is not necessary to remove the Steering Column Control Module (SCCM) from the steering column to replace the left multi-function switch (2). 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the system reserve capacitor to discharge before servicing any airbag or steering column components. 2. Remove both the upper and lower shrouds from the steering column. 3. Remove the one screw (2) that secures the left multi-function switch (3) on the right side of the clockspring (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Service and Repair > Removal > Page 10142 4. Pull the switch (2) straight away from the clockspring (1) far enough to access the electrical connector (3) to disconnect it. 5. Disconnect the instrument panel wiring harness from the back of the left multi-function switch. 6. Remove the switch (2) from the clockspring (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Service and Repair > Removal > Page 10143 Combination Switch: Service and Repair Installation INSTALLATION 1. Position the left multi-function switch in the slot in the back of the clockspring (1) and connect the switch connector (3). 2. Connect the instrument panel wiring harness connector to the back of the left multi-function switch. 3. Align switch (3) with the clockspring (1) and slide toward steering column. 4. Install the screw (2) that secures the switch (3) to the clockspring (1). 5. Install the upper and lower shrouds onto the steering column. 6. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Application and ID Turn Signal Flasher: Application and ID PLEASE NOTE: The Flasher Function for this vehicle is provided by the Totally Integrated Power Module (TIPM). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Front Lamp Unit Bulbs Turn Signal Bulb: Service and Repair Front Lamp Unit Bulbs Removal BULBS 1. Disconnect and isolate the battery negative cable. 2. Hoist vehicle. 3. Working in the appropriate wheel well, loosen up the front of the splash shield, but don't fully remove it. 4. Looking up through the front wheel well, locate the bulb (1) in which needs replacing. The headlamp bulb is the inboard bulb and the park/turn signal bulb is the outboard bulb. 5. Disconnect the bulb electrical connector (2 or 3). NOTE: EXPORT ONLY - If removing/replacing the headlamp bulb on export vehicles there is a rubber cover over the rear of the lamp housing that must be removed to access the bulb. Then a spring clip must be removed and the bulb pulled straight rearward. 6. Grasp the bulb (1), twist 1/4 turn counterclockwise and pull straight out of front lamp unit. Installation BULBS Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Front Lamp Unit Bulbs > Page 10152 1. Reaching up through wheel well, install the headlamp or park/turn signal bulb (1) in the front lamp unit, locking it into place by twisting a 1/4 turn clockwise. NOTE: EXPORT ONLY - If installing/replacing the headlamp bulb on export vehicles push the bulb straight in unit and then install the spring clip. Install the rubber cover over the rear of the lamp housing, over the headlamp bulb. 2. Connect the bulb electrical connector (2 or 3). 3. Install the front of the splash shield (6) removed to gain access to the front lamp unit bulbs. 4. Lower vehicle from hoist. 5. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Front Lamp Unit Bulbs > Page 10153 Turn Signal Bulb: Service and Repair Tail Lamp Unit Bulbs Removal BULBS There are a total of four possible bulbs in the tail lamp unit: - Back-Up Lamp (4) - Park/Brake Lamp (1) - Rear Fog Lamp (5) - Export Only - Turn Signal (3) 1. Remove the tail lamp unit. NOTE: It is not necessary to completely remove the tail lamp unit. Once loosened from quarter panel, there should be enough room to service any of the bulbs. 2. Disconnect the electrical connector. 3. Remove bulb socket from tail lamp unit by twisting a quarter turn counterclockwise. 4. Pull socket straight out of tail lamp unit. 5. Pull bulb from socket. Installation BULBS Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Front Lamp Unit Bulbs > Page 10154 There are a total of four possible bulbs in the tail lamp unit: - Back-Up Lamp (4) - Park/Brake Lamp (1) - Rear Fog Lamp (5) - Export Only - Turn Signal (3) 1. Push bulb into the bulb socket. 2. Install bulb socket into tail lamp assembly. Rotate the socket clockwise until fully seated. 3. Install the tail lamp unit. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Description and Operation > Description Heated Glass Element Switch: Description and Operation Description DESCRIPTION The switch for the rear window defogger (EBL) system (1) is located in the A/C-heater control (2) in the instrument panel center bezel (3). When the rear window defogger switch is pressed to the On position a request signal is sent to the cabin compartment node (CCN), which sends a message to the totally integrated power module (TIPM) to operate the EBL system. When the high side driver in the TIPM is energized, current is directed to the rear defogger grid lines and to the heated side view mirrors (when equipped). The grid lines heat the glass to help clear the surface of fog or frost. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Description and Operation > Description > Page 10161 Heated Glass Element Switch: Description and Operation Operation OPERATION An amber indicator will illuminate when the rear window defogger switch is activated. When activated, the switch sends a request signal to the cabin compartment node (CCN), which sends a message to the totally integrated power module (TIPM) to energize the internal EBL high side driver to provide battery current to the rear window defogger grid lines and to the heated side view mirrors, when equipped. NOTE: The EBL system turns off automatically after 10 minutes of initial operation. Each following activation cycle of the EBL system will last 5 minutes. The EBL system will automatically turn off after an initial programmed time interval of about 10 minutes as long as the ignition switch is in RUN. After the initial time interval has expired, if the rear window defogger switch is pressed to ON again during the same ignition cycle, the EBL system will automatically turn off after about 5 minutes. The EBL system will also turn off if the ignition switch is turned to any position other than RUN or by manually pressing the rear window defogger switch a second time. The rear window defogger switch is diagnosed using a scan tool. The rear window defogger switch and indicator cannot be adjusted or repaired. The A/C-heater control must be replaced if the rear window defogger switch or indicator is found inoperative or damaged. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Description and Operation > Description Heated Glass Element Switch: Description and Operation Description DESCRIPTION The switch for the rear window defogger (EBL) system (1) is located in the A/C-heater control (2) in the instrument panel center bezel (3). When the rear window defogger switch is pressed to the On position a request signal is sent to the cabin compartment node (CCN), which sends a message to the totally integrated power module (TIPM) to operate the EBL system. When the high side driver in the TIPM is energized, current is directed to the rear defogger grid lines and to the heated side view mirrors (when equipped). The grid lines heat the glass to help clear the surface of fog or frost. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Description and Operation > Description > Page 10167 Heated Glass Element Switch: Description and Operation Operation OPERATION An amber indicator will illuminate when the rear window defogger switch is activated. When activated, the switch sends a request signal to the cabin compartment node (CCN), which sends a message to the totally integrated power module (TIPM) to energize the internal EBL high side driver to provide battery current to the rear window defogger grid lines and to the heated side view mirrors, when equipped. NOTE: The EBL system turns off automatically after 10 minutes of initial operation. Each following activation cycle of the EBL system will last 5 minutes. The EBL system will automatically turn off after an initial programmed time interval of about 10 minutes as long as the ignition switch is in RUN. After the initial time interval has expired, if the rear window defogger switch is pressed to ON again during the same ignition cycle, the EBL system will automatically turn off after about 5 minutes. The EBL system will also turn off if the ignition switch is turned to any position other than RUN or by manually pressing the rear window defogger switch a second time. The rear window defogger switch is diagnosed using a scan tool. The rear window defogger switch and indicator cannot be adjusted or repaired. The A/C-heater control must be replaced if the rear window defogger switch or indicator is found inoperative or damaged. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Window-Driver Power Window Switch: Locations Switch-Power Window-Driver Component ID: 349 Component : SWITCH-POWER WINDOW-DRIVER Connector: Name : SWITCH-POWER WINDOW-DRIVER C1 Color : LT. GRAY # of pins : 6 Pin Description Circuit 1 MASTER WINDOW SWITCH LEFT REAR (UP)Q411 14OR/WT 2 MASTER WINDOW SWITCH RIGHT REAR (UP) Q412 14OR/LB 3 MASTER WINDOW SWITCH RIGHT REAR (DOWN) Q612 14OR/DB 4 MASTER WINDOW SWITCH LEFT REAR (DOWN) Q611 14OR/GY 5 MASTER WINDOW SWITCH PASSENGER (DOWN) Q26 14OR/GY 5 RIGHT FRONT WINDOW DRIVER (DOWN) Q22 14OR/VT 6 MASTER WINDOW SWITCH PASSENGER (UP) Q16 14OR/TN 6 RIGHT FRONT WINDOW DRIVER (UP) Q12 14OR/BR Component Location - 54 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Window-Driver > Page 10172 Connector: Name : SWITCH-POWER WINDOW-DRIVER C2 Color : LT. GRAY # of pins : 8 Pin Description Circuit 1-2 IGNITION SWITCH OUTPUT (RUN-ACC) F981 14PK/BR 3 GROUND Z961 20BK/YL 3 GROUND Z929 20BK/PK 4 GROUND Z928 14BK/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Window-Driver > Page 10173 5 WINDOW LOCK OUT SWITCH OUTPUT Q15 14OR/RD 6 LEFT FRONT WINDOW DRIVER (DOWN) Q21 14OR/WT 6 MASTER WINDOW SWITCH PASSENGER (DOWN) Q26 14OR/GY 7 LEFT FRONT WINDOW DRIVER (UP) Q11 14OR/LG 7 MASTER WINDOW SWITCH PASSENGER (UP) Q16 14OR/TN 8 DOOR LOCK SWITCH MUX P697 20LG/DG Component Location - 54 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Window-Driver > Page 10174 Power Window Switch: Locations Switch-Power Window-Left Rear Component ID: 350 Component : SWITCH-POWER WINDOW-LEFT REAR Connector: Name : SWITCH-POWER WINDOW-LEFT REAR Color : LT. GRAY # of pins : 6 Pin Description Circuit 1 MASTER WINDOW SWITCH LEFT REAR (DOWN) Q611 14OR/GY 2 LEFT REAR WINDOW DRIVER (DOWN) Q211 14TN/LB 3 LEFT REAR WINDOW DRIVER (UP) Q111 14TN/YL 4 MASTER WINDOW SWITCH LEFT REAR (UP)Q411 14OR/WT 5-6 WINDOW LOCK OUT SWITCH OUTPUT Q15 14OR/RD Component Location - 56 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Window-Driver > Page 10175 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Window-Driver > Page 10176 Power Window Switch: Locations Switch-Power Window-Passenger Component ID: 351 Component : SWITCH-POWER WINDOW-PASSENGER Connector: Name : SWITCH-POWER WINDOW-PASSENGER Color : LT. GRAY # of pins : 6 Pin Description Circuit 1 MASTER WINDOW SWITCH PASSENGER (DOWN) Q26 14OR/GY 2 RIGHT FRONT WINDOW DRIVER (DOWN) Q22 14OR/VT 2 LEFT FRONT WINDOW DRIVER (DOWN) Q21 14OR/WT 3 RIGHT FRONT WINDOW DRIVER (UP) Q12 14OR/BR 3 LEFT FRONT WINDOW DRIVER (UP) Q11 14OR/LG 4 MASTER WINDOW SWITCH PASSENGER (UP) Q16 14OR/TN 5-- 6 WINDOW LOCK OUT SWITCH OUTPUT Q15 14OR/RD Component Location - 54 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Window-Driver > Page 10177 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Window-Driver > Page 10178 Power Window Switch: Locations Switch-Power Window-Right Rear Component ID: 352 Component : SWITCH-POWER WINDOW-RIGHT REAR Connector: Name : SWITCH-POWER WINDOW-RIGHT REAR Color : LT. GRAY # of pins : 6 Pin Description Circuit 1 MASTER WINDOW SWITCH RIGHT REAR (DOWN) Q612 14OR/DB 2 RIGHT REAR WINDOW DRIVER (DOWN) Q212 14OR/VT 3 RIGHT REAR WINDOW DRIVER (UP) Q112 14OR/BR 4 MASTER WINDOW SWITCH RIGHT REAR (UP) Q412 14OR/LB 5-6 WINDOW LOCK OUT SWITCH OUTPUT Q15 14OR/RD Component Location - 56 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Window-Driver > Page 10179 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Window-Driver Power Window Switch: Diagrams Switch-Power Window-Driver Component ID: 349 Component : SWITCH-POWER WINDOW-DRIVER Connector: Name : SWITCH-POWER WINDOW-DRIVER C1 Color : LT. GRAY # of pins : 6 Pin Description Circuit 1 MASTER WINDOW SWITCH LEFT REAR (UP)Q411 14OR/WT 2 MASTER WINDOW SWITCH RIGHT REAR (UP) Q412 14OR/LB 3 MASTER WINDOW SWITCH RIGHT REAR (DOWN) Q612 14OR/DB 4 MASTER WINDOW SWITCH LEFT REAR (DOWN) Q611 14OR/GY 5 MASTER WINDOW SWITCH PASSENGER (DOWN) Q26 14OR/GY 5 RIGHT FRONT WINDOW DRIVER (DOWN) Q22 14OR/VT 6 MASTER WINDOW SWITCH PASSENGER (UP) Q16 14OR/TN 6 RIGHT FRONT WINDOW DRIVER (UP) Q12 14OR/BR Component Location - 54 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Window-Driver > Page 10182 Connector: Name : SWITCH-POWER WINDOW-DRIVER C2 Color : LT. GRAY # of pins : 8 Pin Description Circuit 1-2 IGNITION SWITCH OUTPUT (RUN-ACC) F981 14PK/BR 3 GROUND Z961 20BK/YL 3 GROUND Z929 20BK/PK 4 GROUND Z928 14BK/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Window-Driver > Page 10183 5 WINDOW LOCK OUT SWITCH OUTPUT Q15 14OR/RD 6 LEFT FRONT WINDOW DRIVER (DOWN) Q21 14OR/WT 6 MASTER WINDOW SWITCH PASSENGER (DOWN) Q26 14OR/GY 7 LEFT FRONT WINDOW DRIVER (UP) Q11 14OR/LG 7 MASTER WINDOW SWITCH PASSENGER (UP) Q16 14OR/TN 8 DOOR LOCK SWITCH MUX P697 20LG/DG Component Location - 54 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Window-Driver > Page 10184 Power Window Switch: Diagrams Switch-Power Window-Left Rear Component ID: 350 Component : SWITCH-POWER WINDOW-LEFT REAR Connector: Name : SWITCH-POWER WINDOW-LEFT REAR Color : LT. GRAY # of pins : 6 Pin Description Circuit 1 MASTER WINDOW SWITCH LEFT REAR (DOWN) Q611 14OR/GY 2 LEFT REAR WINDOW DRIVER (DOWN) Q211 14TN/LB 3 LEFT REAR WINDOW DRIVER (UP) Q111 14TN/YL 4 MASTER WINDOW SWITCH LEFT REAR (UP)Q411 14OR/WT 5-6 WINDOW LOCK OUT SWITCH OUTPUT Q15 14OR/RD Component Location - 56 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Window-Driver > Page 10185 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Window-Driver > Page 10186 Power Window Switch: Diagrams Switch-Power Window-Passenger Component ID: 351 Component : SWITCH-POWER WINDOW-PASSENGER Connector: Name : SWITCH-POWER WINDOW-PASSENGER Color : LT. GRAY # of pins : 6 Pin Description Circuit 1 MASTER WINDOW SWITCH PASSENGER (DOWN) Q26 14OR/GY 2 RIGHT FRONT WINDOW DRIVER (DOWN) Q22 14OR/VT 2 LEFT FRONT WINDOW DRIVER (DOWN) Q21 14OR/WT 3 RIGHT FRONT WINDOW DRIVER (UP) Q12 14OR/BR 3 LEFT FRONT WINDOW DRIVER (UP) Q11 14OR/LG 4 MASTER WINDOW SWITCH PASSENGER (UP) Q16 14OR/TN 5-- 6 WINDOW LOCK OUT SWITCH OUTPUT Q15 14OR/RD Component Location - 54 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Window-Driver > Page 10187 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Window-Driver > Page 10188 Power Window Switch: Diagrams Switch-Power Window-Right Rear Component ID: 352 Component : SWITCH-POWER WINDOW-RIGHT REAR Connector: Name : SWITCH-POWER WINDOW-RIGHT REAR Color : LT. GRAY # of pins : 6 Pin Description Circuit 1 MASTER WINDOW SWITCH RIGHT REAR (DOWN) Q612 14OR/DB 2 RIGHT REAR WINDOW DRIVER (DOWN) Q212 14OR/VT 3 RIGHT REAR WINDOW DRIVER (UP) Q112 14OR/BR 4 MASTER WINDOW SWITCH RIGHT REAR (UP) Q412 14OR/LB 5-6 WINDOW LOCK OUT SWITCH OUTPUT Q15 14OR/RD Component Location - 56 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Window-Driver > Page 10189 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 10190 Power Window Switch: Testing and Inspection DIAGNOSIS AND TESTING - POWER WINDOW SWITCH Remove the switch. Using an ohmmeter, test the window switch for continuity in all positions listed in the Continuity Table. Refer to the Power Window Switch Continuity table to determine if continuity is correct. To test the left front down and express down switch position, connect pin 4 to ground and pin 12 to a 12 volt source. Using a voltmeter, measure for voltage from pin 13 to ground. To test the right front down and express down switch position, connect pin 4 to ground and pin 12 to a 12 volt source. Using a voltmeter, measure for voltage from pin 3 to ground. If the correct results are not obtained, replace the switch. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Removal Power Window Switch: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the front door bolster. 3. Disconnect the electrical harness connectors. 4. With the bolster on the bench, gently pry in on the tabs of the mirror switch and push through the front of the cover and remove. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Removal > Page 10193 Power Window Switch: Service and Repair Installation INSTALLATION 1. Place the mirror switch in bolster opening and firmly snap into place. 2. Connect the electrical harness connectors. 3. Install the front door bolster. 4. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations > Motor-Window-Left Front Power Window Motor: Locations Motor-Window-Left Front Component ID: 169 Component : MOTOR-WINDOW-LEFT FRONT Connector: Name : MOTOR-WINDOW-LEFT FRONT Color : BLACK # of pins : 2 Pin Description Circuit 1 LEFT FRONT WINDOW DRIVER (DOWN) Q21 14OR/WT 2 LEFT FRONT WINDOW DRIVER (UP) Q11 14OR/LG Component Location - 53 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations > Motor-Window-Left Front > Page 10199 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations > Motor-Window-Left Front > Page 10200 Power Window Motor: Locations Motor-Window-Left Rear Component ID: 170 Component : MOTOR-WINDOW-LEFT REAR Connector: Name : MOTOR-WINDOW-LEFT REAR Color : BLACK # of pins : 2 Pin Description Circuit 1 LEFT REAR WINDOW DRIVER (UP) Q111 14TN/YL 2 LEFT REAR WINDOW DRIVER (DOWN) Q211 14TN/LB Component Location - 56 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations > Motor-Window-Left Front > Page 10201 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations > Motor-Window-Left Front > Page 10202 Power Window Motor: Locations Motor-Window-Right Front Component ID: 171 Component : MOTOR-WINDOW-RIGHT FRONT Connector: Name : MOTOR-WINDOW-RIGHT FRONT Color : BLACK # of pins : 2 Pin Description Circuit 1 RIGHT FRONT WINDOW DRIVER (DOWN) Q22 14OR/VT 2 RIGHT FRONT WINDOW DRIVER (UP) Q12 14OR/BR Component Location - 53 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations > Motor-Window-Left Front > Page 10203 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations > Motor-Window-Left Front > Page 10204 Power Window Motor: Locations Motor-Window-Right Rear Component ID: 172 Component : MOTOR-WINDOW-RIGHT REAR Connector: Name : MOTOR-WINDOW-RIGHT REAR Color : BLACK # of pins : 2 Pin Description Circuit 1 RIGHT REAR WINDOW DRIVER (UP) Q112 14OR/BR 2 RIGHT REAR WINDOW DRIVER (DOWN) Q212 14OR/VT Component Location - 56 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations > Motor-Window-Left Front > Page 10205 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Motor-Window-Left Front Power Window Motor: Diagrams Motor-Window-Left Front Component ID: 169 Component : MOTOR-WINDOW-LEFT FRONT Connector: Name : MOTOR-WINDOW-LEFT FRONT Color : BLACK # of pins : 2 Pin Description Circuit 1 LEFT FRONT WINDOW DRIVER (DOWN) Q21 14OR/WT 2 LEFT FRONT WINDOW DRIVER (UP) Q11 14OR/LG Component Location - 53 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Motor-Window-Left Front > Page 10208 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Motor-Window-Left Front > Page 10209 Power Window Motor: Diagrams Motor-Window-Left Rear Component ID: 170 Component : MOTOR-WINDOW-LEFT REAR Connector: Name : MOTOR-WINDOW-LEFT REAR Color : BLACK # of pins : 2 Pin Description Circuit 1 LEFT REAR WINDOW DRIVER (UP) Q111 14TN/YL 2 LEFT REAR WINDOW DRIVER (DOWN) Q211 14TN/LB Component Location - 56 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Motor-Window-Left Front > Page 10210 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Motor-Window-Left Front > Page 10211 Power Window Motor: Diagrams Motor-Window-Right Front Component ID: 171 Component : MOTOR-WINDOW-RIGHT FRONT Connector: Name : MOTOR-WINDOW-RIGHT FRONT Color : BLACK # of pins : 2 Pin Description Circuit 1 RIGHT FRONT WINDOW DRIVER (DOWN) Q22 14OR/VT 2 RIGHT FRONT WINDOW DRIVER (UP) Q12 14OR/BR Component Location - 53 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Motor-Window-Left Front > Page 10212 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Motor-Window-Left Front > Page 10213 Power Window Motor: Diagrams Motor-Window-Right Rear Component ID: 172 Component : MOTOR-WINDOW-RIGHT REAR Connector: Name : MOTOR-WINDOW-RIGHT REAR Color : BLACK # of pins : 2 Pin Description Circuit 1 RIGHT REAR WINDOW DRIVER (UP) Q112 14OR/BR 2 RIGHT REAR WINDOW DRIVER (DOWN) Q212 14OR/VT Component Location - 56 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Motor-Window-Left Front > Page 10214 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Description and Operation > Description Power Window Motor: Description and Operation Description DESCRIPTION The window regulator modules are directly connected to each of the front door window regulator motors. The window switches are hard wired by a MUX circuit to the respective window regulator module. The respective rear window motor is hard wired to the module. The front window motor is directly attached to the module. Both front door window switches have the express down feature. The module will cease lowering the front glass when a fully down position is sensed through the hall effect sensor. When a module must be replaced, it is necessary to replace the entire regulator assembly. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Description and Operation > Description > Page 10217 Power Window Motor: Description and Operation Operation OPERATION When a door is opened, the respective module will receive a signal from the door ajar switch or the window drop switch. The window drop switch is directly controlled by both the interior and the exterior door handle switches. The drop switch is part of the door latch. This switch is faster than the door ajar switch to signal an open door operation. At that point the module will drop the front door glass 10 mm (0.5 in). However, if the window drop switch should fail, the door ajar sense would also drop the window 10 mm (0.5 in) and the module would set a trouble code. When the module then receives a door ajar switch open (door closed) it would raise the window 10 mm (0.5 in). The module knows the position of the window by counting the motor rotation through the hall effect sensor in the module. If a door window is raised while that door is open, the module will raise the glass up, but when the door is closed it will raise the glass an additional 10 mm (0.5 in). When the convertible top down switch is pressed to the first detent, input is received by the driver window regulator module and passenger window regulator module, which will lower the front windows approximately 40 mm (1.6 in), and lower the rear windows approximately 55 mm (2.0 in). After a 200 ms delay, it energizes the power top down relay to lower the convertible top. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Description and Operation > Page 10218 Power Window Motor: Testing and Inspection WINDOW REGULATOR MODULE Any diagnosis of the Window Regulator Modules should begin with the use of the scan tool. For information on the use of the scan tool, refer to the appropriate Diagnostic Service Information. For complete circuit diagrams, refer to the appropriate wiring information. WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Removal Power Window Motor: Service and Repair Removal REMOVAL 1. Move the window to the full UP position, if possible. 2. Disconnect and isolate the battery negative cable. 3. Remove the front door module. 4. Disconnect electrical harness connector from motor. 5. Remove window regulator. 6. With regulator on bench, remove four screws retaining the motor to the regulator and remove motor. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Removal > Page 10221 Power Window Motor: Service and Repair Installation INSTALLATION 1. With regulator on bench, install four screws retaining the motor to the regulator. 2. Install the window regulator. 3. Connect the electrical harness connector to window motor. 4. Install the door module. 5. Connect battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Switch-Power Window-Driver Power Window Switch: Locations Switch-Power Window-Driver Component ID: 349 Component : SWITCH-POWER WINDOW-DRIVER Connector: Name : SWITCH-POWER WINDOW-DRIVER C1 Color : LT. GRAY # of pins : 6 Pin Description Circuit 1 MASTER WINDOW SWITCH LEFT REAR (UP)Q411 14OR/WT 2 MASTER WINDOW SWITCH RIGHT REAR (UP) Q412 14OR/LB 3 MASTER WINDOW SWITCH RIGHT REAR (DOWN) Q612 14OR/DB 4 MASTER WINDOW SWITCH LEFT REAR (DOWN) Q611 14OR/GY 5 MASTER WINDOW SWITCH PASSENGER (DOWN) Q26 14OR/GY 5 RIGHT FRONT WINDOW DRIVER (DOWN) Q22 14OR/VT 6 MASTER WINDOW SWITCH PASSENGER (UP) Q16 14OR/TN 6 RIGHT FRONT WINDOW DRIVER (UP) Q12 14OR/BR Component Location - 54 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Switch-Power Window-Driver > Page 10226 Connector: Name : SWITCH-POWER WINDOW-DRIVER C2 Color : LT. GRAY # of pins : 8 Pin Description Circuit 1-2 IGNITION SWITCH OUTPUT (RUN-ACC) F981 14PK/BR 3 GROUND Z961 20BK/YL 3 GROUND Z929 20BK/PK 4 GROUND Z928 14BK/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Switch-Power Window-Driver > Page 10227 5 WINDOW LOCK OUT SWITCH OUTPUT Q15 14OR/RD 6 LEFT FRONT WINDOW DRIVER (DOWN) Q21 14OR/WT 6 MASTER WINDOW SWITCH PASSENGER (DOWN) Q26 14OR/GY 7 LEFT FRONT WINDOW DRIVER (UP) Q11 14OR/LG 7 MASTER WINDOW SWITCH PASSENGER (UP) Q16 14OR/TN 8 DOOR LOCK SWITCH MUX P697 20LG/DG Component Location - 54 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Switch-Power Window-Driver > Page 10228 Power Window Switch: Locations Switch-Power Window-Left Rear Component ID: 350 Component : SWITCH-POWER WINDOW-LEFT REAR Connector: Name : SWITCH-POWER WINDOW-LEFT REAR Color : LT. GRAY # of pins : 6 Pin Description Circuit 1 MASTER WINDOW SWITCH LEFT REAR (DOWN) Q611 14OR/GY 2 LEFT REAR WINDOW DRIVER (DOWN) Q211 14TN/LB 3 LEFT REAR WINDOW DRIVER (UP) Q111 14TN/YL 4 MASTER WINDOW SWITCH LEFT REAR (UP)Q411 14OR/WT 5-6 WINDOW LOCK OUT SWITCH OUTPUT Q15 14OR/RD Component Location - 56 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Switch-Power Window-Driver > Page 10229 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Switch-Power Window-Driver > Page 10230 Power Window Switch: Locations Switch-Power Window-Passenger Component ID: 351 Component : SWITCH-POWER WINDOW-PASSENGER Connector: Name : SWITCH-POWER WINDOW-PASSENGER Color : LT. GRAY # of pins : 6 Pin Description Circuit 1 MASTER WINDOW SWITCH PASSENGER (DOWN) Q26 14OR/GY 2 RIGHT FRONT WINDOW DRIVER (DOWN) Q22 14OR/VT 2 LEFT FRONT WINDOW DRIVER (DOWN) Q21 14OR/WT 3 RIGHT FRONT WINDOW DRIVER (UP) Q12 14OR/BR 3 LEFT FRONT WINDOW DRIVER (UP) Q11 14OR/LG 4 MASTER WINDOW SWITCH PASSENGER (UP) Q16 14OR/TN 5-- 6 WINDOW LOCK OUT SWITCH OUTPUT Q15 14OR/RD Component Location - 54 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Switch-Power Window-Driver > Page 10231 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Switch-Power Window-Driver > Page 10232 Power Window Switch: Locations Switch-Power Window-Right Rear Component ID: 352 Component : SWITCH-POWER WINDOW-RIGHT REAR Connector: Name : SWITCH-POWER WINDOW-RIGHT REAR Color : LT. GRAY # of pins : 6 Pin Description Circuit 1 MASTER WINDOW SWITCH RIGHT REAR (DOWN) Q612 14OR/DB 2 RIGHT REAR WINDOW DRIVER (DOWN) Q212 14OR/VT 3 RIGHT REAR WINDOW DRIVER (UP) Q112 14OR/BR 4 MASTER WINDOW SWITCH RIGHT REAR (UP) Q412 14OR/LB 5-6 WINDOW LOCK OUT SWITCH OUTPUT Q15 14OR/RD Component Location - 56 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Switch-Power Window-Driver > Page 10233 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Switch-Power Window-Driver Power Window Switch: Diagrams Switch-Power Window-Driver Component ID: 349 Component : SWITCH-POWER WINDOW-DRIVER Connector: Name : SWITCH-POWER WINDOW-DRIVER C1 Color : LT. GRAY # of pins : 6 Pin Description Circuit 1 MASTER WINDOW SWITCH LEFT REAR (UP)Q411 14OR/WT 2 MASTER WINDOW SWITCH RIGHT REAR (UP) Q412 14OR/LB 3 MASTER WINDOW SWITCH RIGHT REAR (DOWN) Q612 14OR/DB 4 MASTER WINDOW SWITCH LEFT REAR (DOWN) Q611 14OR/GY 5 MASTER WINDOW SWITCH PASSENGER (DOWN) Q26 14OR/GY 5 RIGHT FRONT WINDOW DRIVER (DOWN) Q22 14OR/VT 6 MASTER WINDOW SWITCH PASSENGER (UP) Q16 14OR/TN 6 RIGHT FRONT WINDOW DRIVER (UP) Q12 14OR/BR Component Location - 54 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Switch-Power Window-Driver > Page 10236 Connector: Name : SWITCH-POWER WINDOW-DRIVER C2 Color : LT. GRAY # of pins : 8 Pin Description Circuit 1-2 IGNITION SWITCH OUTPUT (RUN-ACC) F981 14PK/BR 3 GROUND Z961 20BK/YL 3 GROUND Z929 20BK/PK 4 GROUND Z928 14BK/LG Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Switch-Power Window-Driver > Page 10237 5 WINDOW LOCK OUT SWITCH OUTPUT Q15 14OR/RD 6 LEFT FRONT WINDOW DRIVER (DOWN) Q21 14OR/WT 6 MASTER WINDOW SWITCH PASSENGER (DOWN) Q26 14OR/GY 7 LEFT FRONT WINDOW DRIVER (UP) Q11 14OR/LG 7 MASTER WINDOW SWITCH PASSENGER (UP) Q16 14OR/TN 8 DOOR LOCK SWITCH MUX P697 20LG/DG Component Location - 54 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Switch-Power Window-Driver > Page 10238 Power Window Switch: Diagrams Switch-Power Window-Left Rear Component ID: 350 Component : SWITCH-POWER WINDOW-LEFT REAR Connector: Name : SWITCH-POWER WINDOW-LEFT REAR Color : LT. GRAY # of pins : 6 Pin Description Circuit 1 MASTER WINDOW SWITCH LEFT REAR (DOWN) Q611 14OR/GY 2 LEFT REAR WINDOW DRIVER (DOWN) Q211 14TN/LB 3 LEFT REAR WINDOW DRIVER (UP) Q111 14TN/YL 4 MASTER WINDOW SWITCH LEFT REAR (UP)Q411 14OR/WT 5-6 WINDOW LOCK OUT SWITCH OUTPUT Q15 14OR/RD Component Location - 56 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Switch-Power Window-Driver > Page 10239 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Switch-Power Window-Driver > Page 10240 Power Window Switch: Diagrams Switch-Power Window-Passenger Component ID: 351 Component : SWITCH-POWER WINDOW-PASSENGER Connector: Name : SWITCH-POWER WINDOW-PASSENGER Color : LT. GRAY # of pins : 6 Pin Description Circuit 1 MASTER WINDOW SWITCH PASSENGER (DOWN) Q26 14OR/GY 2 RIGHT FRONT WINDOW DRIVER (DOWN) Q22 14OR/VT 2 LEFT FRONT WINDOW DRIVER (DOWN) Q21 14OR/WT 3 RIGHT FRONT WINDOW DRIVER (UP) Q12 14OR/BR 3 LEFT FRONT WINDOW DRIVER (UP) Q11 14OR/LG 4 MASTER WINDOW SWITCH PASSENGER (UP) Q16 14OR/TN 5-- 6 WINDOW LOCK OUT SWITCH OUTPUT Q15 14OR/RD Component Location - 54 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Switch-Power Window-Driver > Page 10241 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Switch-Power Window-Driver > Page 10242 Power Window Switch: Diagrams Switch-Power Window-Right Rear Component ID: 352 Component : SWITCH-POWER WINDOW-RIGHT REAR Connector: Name : SWITCH-POWER WINDOW-RIGHT REAR Color : LT. GRAY # of pins : 6 Pin Description Circuit 1 MASTER WINDOW SWITCH RIGHT REAR (DOWN) Q612 14OR/DB 2 RIGHT REAR WINDOW DRIVER (DOWN) Q212 14OR/VT 3 RIGHT REAR WINDOW DRIVER (UP) Q112 14OR/BR 4 MASTER WINDOW SWITCH RIGHT REAR (UP) Q412 14OR/LB 5-6 WINDOW LOCK OUT SWITCH OUTPUT Q15 14OR/RD Component Location - 56 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Switch-Power Window-Driver > Page 10243 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Page 10244 Power Window Switch: Testing and Inspection DIAGNOSIS AND TESTING - POWER WINDOW SWITCH Remove the switch. Using an ohmmeter, test the window switch for continuity in all positions listed in the Continuity Table. Refer to the Power Window Switch Continuity table to determine if continuity is correct. To test the left front down and express down switch position, connect pin 4 to ground and pin 12 to a 12 volt source. Using a voltmeter, measure for voltage from pin 13 to ground. To test the right front down and express down switch position, connect pin 4 to ground and pin 12 to a 12 volt source. Using a voltmeter, measure for voltage from pin 3 to ground. If the correct results are not obtained, replace the switch. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Removal Power Window Switch: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the front door bolster. 3. Disconnect the electrical harness connectors. 4. With the bolster on the bench, gently pry in on the tabs of the mirror switch and push through the front of the cover and remove. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Removal > Page 10247 Power Window Switch: Service and Repair Installation INSTALLATION 1. Place the mirror switch in bolster opening and firmly snap into place. 2. Connect the electrical harness connectors. 3. Install the front door bolster. 4. Connect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Service and Repair > Removal Front Door Window Glass: Service and Repair Removal REMOVAL 1. Remove bolster. 2. Move glass to line up snap plates with access holes (1). 3. Using a punch or equivalent, press tabs releasing glass from window regulator. 4. Manually move glass upward to full up position and remove from window frame. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Service and Repair > Removal > Page 10253 Front Door Window Glass: Service and Repair Installation INSTALLATION 1. Insert glass into glass channel and slide down ensuring access holes (1) align with snaps. 2. Ensure access holes properly lock into snaps (1). 3. Install bolster. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair Liftgate Window Glass: Service and Repair Liftgate Removal 1. Open liftgate. 2. Disconnect washer hose. 3. Disconnect liftgate harness (1). 4. Disconnect cable from handle. 5. With the help from an assistant, support liftgate and disconnect Prop rods. 6. Remove fasteners (2) attaching liftgate (1) to liftgate hinge (3). Installation Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair > Page 10257 1. With the help of an assistant, place liftgate (1) onto liftgate hinges (3). 2. Torque nuts (2) to 15 Nm (11 ft. lbs.). 3. Install prop. rods. 4. Install liftgate harness (1). 5. Install washer hose. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Removal Quarter Window Glass: Service and Repair Removal REMOVAL 1. Before proceeding with the following repair procedure, review all warnings and cautions. Refer to Windows and Glass/Service Precautions. 2. Remove the quarter panel trim from the side of the vehicle being serviced. Refer to Trim Panel. CAUTION: Be careful not to damage painted surfaces when removing moldings or cutting urethane around the windshield. 3. Using razor knife, cut the urethane adhesive that secures the quarter glass (1) to window fence (2). 4. Carefully push the quarter window glass from the opening. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Removal > Page 10262 Quarter Window Glass: Service and Repair Installation INSTALLATION NOTE: Grand Cherokee shown, Caliber similar. WARNING: Do not operate the vehicle within 24 hours of quarter glass installation. It takes at least 24 hours for urethane adhesive to cure. If it is not cured, the quarter glass may not perform properly if the vehicle is in an accident. CAUTION: To help prevent water leaks, partially roll down the left and right door glass before installing the quarter glass. This avoids pressurizing the passenger compartment if a door is slammed before the urethane is cured. CAUTION: Protect all painted and trimmed surfaces from coming in contact with urethane or primers. NOTE: To prevent corrosion, do not damage paint on the quarter glass fence when removing original urethane. NOTE: The quarter glass fence should be cleaned of most of its old urethane adhesive. A small amount of old urethane, approximately 1 mm (.04 in.) in height should remain on the fence. Do not completely remove all old urethane from the fence, the paint finish and bonding strength will be adversely affected. 1. Using a razor knife, level the original bead of urethane on the fence to a thickness of approximately 1 mm (0.04 in.). 2. If the quarter glass is being reused, remove as much of the original urethane as possible from the glass surface using a razor knife. WARNING: Do not use solvent based glass cleaners to clean the quarter glass before applying glass prep and primer or poor glass adhesion may result. 3. Clean the inside of the quarter glass with an ammonia based glass cleaner and a lint-free cloth. 4. Apply glass prep adhesion promoter 25 mm (1 in.) wide around the perimeter of the glass and 5 mm (0.2 in.) from the edge of the glass and wipe dry with a clean lint-free cloth until no streaks are visible. 5. Apply glass primer 25 mm (1 in.) wide around the perimeter of the glass and 5 mm (0.2 in.) from the edge of the glass. Allow at least three minutes drying time. 6. Using a flashlight, verify that the primer is completely and evenly installed along the perimeter of the quarter glass. 7. Re-prime any area that is not fully and evenly primed. 8. Clean the quarter glass fence with an ammonia based glass cleaner and a lint-free cloth. 9. Apply pinch weld primer 15 mm (0.75 in.) wide around the quarter glass fence. Allow at least three minutes drying time. 10. Using a flashlight, verify that the primer is completely and evenly installed along the quarter glass fence. 11. Re-prime any area that is not fully and evenly primed. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Removal > Page 10263 CAUTION: Always apply the bead of adhesive to the quarter glass. Always install the quarter glass within 5 minutes after applying the adhesive. NOTE: If the original urethane adhesive has been exposed for more than 12 hours, the entire adhesive area will need to be re-primed prior to installing new adhesive. 12. Apply approximately a 10 mm (0.4 in.) wide bead of adhesive with a triangular nozzle approximately 6 mm (0.230 in.) from the edge of the glass starting at the bottom center of the quarter glass. 13. Run the end of the adhesive bead on the quarter glass parallel to the start of the bead and smooth the ends flush. 14. Place the quarter glass (1) into the window opening (2) and insert mounting studs through the holes in the window fence. 15. Install the headliner. 16. Install the quarter panel trim. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System Information > Service and Repair > Removal Rear Door Window Glass: Service and Repair Removal REMOVAL 1. Remove speaker and grille. 2. Remove bolster. 3. Remove door module. 4. Raise window (5) gaining access to window tabs. 5. With a punch or equivalent, press regulator tabs holding window in regulator (3). 6. Carefully, remove window (5). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System Information > Service and Repair > Removal > Page 10268 Rear Door Window Glass: Service and Repair Installation INSTALLATION 1. Install window regulator to door panel. 2. Install glass (1) down through window channel into window regulator (2) ensuring glass properly seats in access holes. 3. Connect wire connectors. 4. Install door module. 5. Install bolster. 6. Install speaker and grille. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Technical Service Bulletins > Customer Interest for Front Door Window Regulator: > 23-028-08 > Sep > 08 > Body - Noise When Operating Front/Rear Door Windows Front Door Window Regulator: Customer Interest Body - Noise When Operating Front/Rear Door Windows NUMBER: 23-028-08 GROUP: Body DATE: September 19, 2008 SUBJECT: Squeak or Groan Sound When Raising or Lowering Door Glass OVERVIEW: This bulletin involves lubricating the window regulator rails. MODELS: 2006 - 2007 (CS) Pacifica 2007 - 2008 (LX) 300/Magnum/Charger 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber NOTE: This bulletin applies to all 2006 - 2007 CS, 2007 - 2008 LX vehicles built before November 14th, 2007 (MDH 1114XX) and PM/MK vehicles built before May 13th 2008 (MDH 0513XX). SYMPTOM/CONDITION: Squeak or squealing sound from window regulator area when raising or lowering front or rear door glass. Groaning sound when cycling front or rear door glass to full up position. DIAGNOSIS: If the customer describes the Symptom/Condition, verify the sound is from the regulator and is not being caused by glass run seals or belt seals. If the condition is present, perform the Repair Procedure on the door. PARTS REQUIRED: REPAIR PROCEDURE - PM/MK: 1. Remove door trim bolster. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > PANEL, Door Trim > Removal > REMOVAL. 2. Remove the door speaker cover and speaker. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 08 - Electrical > 8A - Audio > Speaker > Removal > Removal. 3. Lower regulator to a position where forward (white) slider is visible through opening. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Technical Service Bulletins > Customer Interest for Front Door Window Regulator: > 23-028-08 > Sep > 08 > Body - Noise When Operating Front/Rear Door Windows > Page 10278 4. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers (Fig 1). 5. Move regulator to position where rear (white) slider is visible through opening. 6. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers (Fig 2). 7. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 8. Install the door speaker and cover. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 08 - Electrical > 8A - Audio > Speaker > Installation > Installation. 9. Install door trim bolster. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 10. Repeat the lubrication process only on doors that have a regulator squeak or groan sound issue. REPAIR PROCEDURE - CS: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Technical Service Bulletins > Customer Interest for Front Door Window Regulator: > 23-028-08 > Sep > 08 > Body - Noise When Operating Front/Rear Door Windows > Page 10279 1. Remove door trim panel and watershield to access regulator rails and sliders. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Removal > Removal. 2. Lower regulator to a position where forward (white) slider is visible through opening. 3. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 4. Move regulator to position where rear (white) slider is visible through opening. 5. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 6. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 7. Install watershield and door trim panel. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 8. Repeat the lubrication process only on doors that have a regulator squeak or groan issue. REPAIR PROCEDURE - LX: 1. Remove door trim panel and watershield to access regulator rails and sliders. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Removal > Removal. 2. Lower regulator to a position where forward (white) slider is visible through opening. 3. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 4. Move regulator to position where rear (white) slider is visible through opening. 5. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 6. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 7. Install watershield and door trim panel. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 8. Repeat the lubrication process only on doors that have a regulator squeak or groan issue. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Technical Service Bulletins > Customer Interest for Front Door Window Regulator: > 23-028-08 > Sep > 08 > Body - Noise When Operating Front/Rear Door Windows > Page 10280 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > 23-028-08 > Sep > 08 > Body - Noise When Operating Front/Rear Door Windows Front Door Window Regulator: All Technical Service Bulletins Body - Noise When Operating Front/Rear Door Windows NUMBER: 23-028-08 GROUP: Body DATE: September 19, 2008 SUBJECT: Squeak or Groan Sound When Raising or Lowering Door Glass OVERVIEW: This bulletin involves lubricating the window regulator rails. MODELS: 2006 - 2007 (CS) Pacifica 2007 - 2008 (LX) 300/Magnum/Charger 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber NOTE: This bulletin applies to all 2006 - 2007 CS, 2007 - 2008 LX vehicles built before November 14th, 2007 (MDH 1114XX) and PM/MK vehicles built before May 13th 2008 (MDH 0513XX). SYMPTOM/CONDITION: Squeak or squealing sound from window regulator area when raising or lowering front or rear door glass. Groaning sound when cycling front or rear door glass to full up position. DIAGNOSIS: If the customer describes the Symptom/Condition, verify the sound is from the regulator and is not being caused by glass run seals or belt seals. If the condition is present, perform the Repair Procedure on the door. PARTS REQUIRED: REPAIR PROCEDURE - PM/MK: 1. Remove door trim bolster. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > PANEL, Door Trim > Removal > REMOVAL. 2. Remove the door speaker cover and speaker. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 08 - Electrical > 8A - Audio > Speaker > Removal > Removal. 3. Lower regulator to a position where forward (white) slider is visible through opening. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > 23-028-08 > Sep > 08 > Body - Noise When Operating Front/Rear Door Windows > Page 10286 4. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers (Fig 1). 5. Move regulator to position where rear (white) slider is visible through opening. 6. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers (Fig 2). 7. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 8. Install the door speaker and cover. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 08 - Electrical > 8A - Audio > Speaker > Installation > Installation. 9. Install door trim bolster. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 10. Repeat the lubrication process only on doors that have a regulator squeak or groan sound issue. REPAIR PROCEDURE - CS: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > 23-028-08 > Sep > 08 > Body - Noise When Operating Front/Rear Door Windows > Page 10287 1. Remove door trim panel and watershield to access regulator rails and sliders. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Removal > Removal. 2. Lower regulator to a position where forward (white) slider is visible through opening. 3. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 4. Move regulator to position where rear (white) slider is visible through opening. 5. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 6. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 7. Install watershield and door trim panel. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 8. Repeat the lubrication process only on doors that have a regulator squeak or groan issue. REPAIR PROCEDURE - LX: 1. Remove door trim panel and watershield to access regulator rails and sliders. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Removal > Removal. 2. Lower regulator to a position where forward (white) slider is visible through opening. 3. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 4. Move regulator to position where rear (white) slider is visible through opening. 5. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 6. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 7. Install watershield and door trim panel. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 8. Repeat the lubrication process only on doors that have a regulator squeak or groan issue. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > 23-028-08 > Sep > 08 > Body - Noise When Operating Front/Rear Door Windows > Page 10288 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page 10289 Front Door Window Regulator: By Symptom Technical Service Bulletin # 23-028-08 Date: 080919 Body - Noise When Operating Front/Rear Door Windows NUMBER: 23-028-08 GROUP: Body DATE: September 19, 2008 SUBJECT: Squeak or Groan Sound When Raising or Lowering Door Glass OVERVIEW: This bulletin involves lubricating the window regulator rails. MODELS: 2006 - 2007 (CS) Pacifica 2007 - 2008 (LX) 300/Magnum/Charger 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber NOTE: This bulletin applies to all 2006 - 2007 CS, 2007 - 2008 LX vehicles built before November 14th, 2007 (MDH 1114XX) and PM/MK vehicles built before May 13th 2008 (MDH 0513XX). SYMPTOM/CONDITION: Squeak or squealing sound from window regulator area when raising or lowering front or rear door glass. Groaning sound when cycling front or rear door glass to full up position. DIAGNOSIS: If the customer describes the Symptom/Condition, verify the sound is from the regulator and is not being caused by glass run seals or belt seals. If the condition is present, perform the Repair Procedure on the door. PARTS REQUIRED: REPAIR PROCEDURE - PM/MK: 1. Remove door trim bolster. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > PANEL, Door Trim > Removal > REMOVAL. 2. Remove the door speaker cover and speaker. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 08 - Electrical > 8A - Audio > Speaker > Removal > Removal. 3. Lower regulator to a position where forward (white) slider is visible through opening. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page 10290 4. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers (Fig 1). 5. Move regulator to position where rear (white) slider is visible through opening. 6. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers (Fig 2). 7. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 8. Install the door speaker and cover. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 08 - Electrical > 8A - Audio > Speaker > Installation > Installation. 9. Install door trim bolster. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 10. Repeat the lubrication process only on doors that have a regulator squeak or groan sound issue. REPAIR PROCEDURE - CS: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page 10291 1. Remove door trim panel and watershield to access regulator rails and sliders. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Removal > Removal. 2. Lower regulator to a position where forward (white) slider is visible through opening. 3. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 4. Move regulator to position where rear (white) slider is visible through opening. 5. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 6. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 7. Install watershield and door trim panel. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 8. Repeat the lubrication process only on doors that have a regulator squeak or groan issue. REPAIR PROCEDURE - LX: 1. Remove door trim panel and watershield to access regulator rails and sliders. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Removal > Removal. 2. Lower regulator to a position where forward (white) slider is visible through opening. 3. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 4. Move regulator to position where rear (white) slider is visible through opening. 5. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 6. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 7. Install watershield and door trim panel. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 8. Repeat the lubrication process only on doors that have a regulator squeak or groan issue. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page 10292 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 23-028-08 Date: 080919 Body - Noise When Operating Front/Rear Door Windows NUMBER: 23-028-08 GROUP: Body DATE: September 19, 2008 SUBJECT: Squeak or Groan Sound When Raising or Lowering Door Glass OVERVIEW: This bulletin involves lubricating the window regulator rails. MODELS: 2006 - 2007 (CS) Pacifica 2007 - 2008 (LX) 300/Magnum/Charger 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber NOTE: This bulletin applies to all 2006 - 2007 CS, 2007 - 2008 LX vehicles built before November 14th, 2007 (MDH 1114XX) and PM/MK vehicles built before May 13th 2008 (MDH 0513XX). SYMPTOM/CONDITION: Squeak or squealing sound from window regulator area when raising or lowering front or rear door glass. Groaning sound when cycling front or rear door glass to full up position. DIAGNOSIS: If the customer describes the Symptom/Condition, verify the sound is from the regulator and is not being caused by glass run seals or belt seals. If the condition is present, perform the Repair Procedure on the door. PARTS REQUIRED: REPAIR PROCEDURE - PM/MK: 1. Remove door trim bolster. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > PANEL, Door Trim > Removal > REMOVAL. 2. Remove the door speaker cover and speaker. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 08 - Electrical > 8A - Audio > Speaker > Removal > Removal. 3. Lower regulator to a position where forward (white) slider is visible through opening. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page 10293 4. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers (Fig 1). 5. Move regulator to position where rear (white) slider is visible through opening. 6. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers (Fig 2). 7. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 8. Install the door speaker and cover. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 08 - Electrical > 8A - Audio > Speaker > Installation > Installation. 9. Install door trim bolster. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 10. Repeat the lubrication process only on doors that have a regulator squeak or groan sound issue. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page 10294 REPAIR PROCEDURE - CS: 1. Remove door trim panel and watershield to access regulator rails and sliders. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Removal > Removal. 2. Lower regulator to a position where forward (white) slider is visible through opening. 3. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 4. Move regulator to position where rear (white) slider is visible through opening. 5. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 6. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 7. Install watershield and door trim panel. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 8. Repeat the lubrication process only on doors that have a regulator squeak or groan issue. REPAIR PROCEDURE - LX: 1. Remove door trim panel and watershield to access regulator rails and sliders. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Removal > Removal. 2. Lower regulator to a position where forward (white) slider is visible through opening. 3. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 4. Move regulator to position where rear (white) slider is visible through opening. 5. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 6. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 7. Install watershield and door trim panel. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 8. Repeat the lubrication process only on doors that have a regulator squeak or groan issue. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page 10295 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Removal Front Door Window Regulator: Service and Repair Removal REMOVAL 1. Remove bolster. 2. Remove door plugs. 3. If equipped, remove window crank (1). 4. Remove glass. 5. Remove power motor attachment screws (1) from front side of trim panel. (For manual windows only, unsnap manual drive from drum housing). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Removal > Page 10298 6. Remove lower attachment bolts through front side of trim panel for Window Regulator rails (7). CAUTION: Use care when disconnecting connectors to avoid damaging components. 7. Disconnect wire harness (10) from power motor on back of trim panel. 8. Remove rails for towers on back side of trim panel. 9. Remove window regulator (5) from trim panel. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Removal > Page 10299 Front Door Window Regulator: Service and Repair Installation INSTALLATION 1. Install window regulator (5) to door module (6). 2. Install rails (5) back to trim panel. CAUTION: Use care when connecting connectors to avoid damaging components. 3. Connect wire harness (10). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Technical Service Bulletins > Customer Interest for Rear Door Window Regulator: > 23-028-08 > Sep > 08 > Body - Noise When Operating Front/Rear Door Windows Rear Door Window Regulator: Customer Interest Body - Noise When Operating Front/Rear Door Windows NUMBER: 23-028-08 GROUP: Body DATE: September 19, 2008 SUBJECT: Squeak or Groan Sound When Raising or Lowering Door Glass OVERVIEW: This bulletin involves lubricating the window regulator rails. MODELS: 2006 - 2007 (CS) Pacifica 2007 - 2008 (LX) 300/Magnum/Charger 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber NOTE: This bulletin applies to all 2006 - 2007 CS, 2007 - 2008 LX vehicles built before November 14th, 2007 (MDH 1114XX) and PM/MK vehicles built before May 13th 2008 (MDH 0513XX). SYMPTOM/CONDITION: Squeak or squealing sound from window regulator area when raising or lowering front or rear door glass. Groaning sound when cycling front or rear door glass to full up position. DIAGNOSIS: If the customer describes the Symptom/Condition, verify the sound is from the regulator and is not being caused by glass run seals or belt seals. If the condition is present, perform the Repair Procedure on the door. PARTS REQUIRED: REPAIR PROCEDURE - PM/MK: 1. Remove door trim bolster. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > PANEL, Door Trim > Removal > REMOVAL. 2. Remove the door speaker cover and speaker. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 08 - Electrical > 8A - Audio > Speaker > Removal > Removal. 3. Lower regulator to a position where forward (white) slider is visible through opening. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Technical Service Bulletins > Customer Interest for Rear Door Window Regulator: > 23-028-08 > Sep > 08 > Body - Noise When Operating Front/Rear Door Windows > Page 10308 4. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers (Fig 1). 5. Move regulator to position where rear (white) slider is visible through opening. 6. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers (Fig 2). 7. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 8. Install the door speaker and cover. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 08 - Electrical > 8A - Audio > Speaker > Installation > Installation. 9. Install door trim bolster. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 10. Repeat the lubrication process only on doors that have a regulator squeak or groan sound issue. REPAIR PROCEDURE - CS: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Technical Service Bulletins > Customer Interest for Rear Door Window Regulator: > 23-028-08 > Sep > 08 > Body - Noise When Operating Front/Rear Door Windows > Page 10309 1. Remove door trim panel and watershield to access regulator rails and sliders. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Removal > Removal. 2. Lower regulator to a position where forward (white) slider is visible through opening. 3. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 4. Move regulator to position where rear (white) slider is visible through opening. 5. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 6. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 7. Install watershield and door trim panel. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 8. Repeat the lubrication process only on doors that have a regulator squeak or groan issue. REPAIR PROCEDURE - LX: 1. Remove door trim panel and watershield to access regulator rails and sliders. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Removal > Removal. 2. Lower regulator to a position where forward (white) slider is visible through opening. 3. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 4. Move regulator to position where rear (white) slider is visible through opening. 5. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 6. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 7. Install watershield and door trim panel. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 8. Repeat the lubrication process only on doors that have a regulator squeak or groan issue. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Technical Service Bulletins > Customer Interest for Rear Door Window Regulator: > 23-028-08 > Sep > 08 > Body - Noise When Operating Front/Rear Door Windows > Page 10310 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > 23-028-08 > Sep > 08 > Body - Noise When Operating Front/Rear Door Windows Rear Door Window Regulator: All Technical Service Bulletins Body - Noise When Operating Front/Rear Door Windows NUMBER: 23-028-08 GROUP: Body DATE: September 19, 2008 SUBJECT: Squeak or Groan Sound When Raising or Lowering Door Glass OVERVIEW: This bulletin involves lubricating the window regulator rails. MODELS: 2006 - 2007 (CS) Pacifica 2007 - 2008 (LX) 300/Magnum/Charger 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber NOTE: This bulletin applies to all 2006 - 2007 CS, 2007 - 2008 LX vehicles built before November 14th, 2007 (MDH 1114XX) and PM/MK vehicles built before May 13th 2008 (MDH 0513XX). SYMPTOM/CONDITION: Squeak or squealing sound from window regulator area when raising or lowering front or rear door glass. Groaning sound when cycling front or rear door glass to full up position. DIAGNOSIS: If the customer describes the Symptom/Condition, verify the sound is from the regulator and is not being caused by glass run seals or belt seals. If the condition is present, perform the Repair Procedure on the door. PARTS REQUIRED: REPAIR PROCEDURE - PM/MK: 1. Remove door trim bolster. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > PANEL, Door Trim > Removal > REMOVAL. 2. Remove the door speaker cover and speaker. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 08 - Electrical > 8A - Audio > Speaker > Removal > Removal. 3. Lower regulator to a position where forward (white) slider is visible through opening. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > 23-028-08 > Sep > 08 > Body - Noise When Operating Front/Rear Door Windows > Page 10316 4. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers (Fig 1). 5. Move regulator to position where rear (white) slider is visible through opening. 6. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers (Fig 2). 7. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 8. Install the door speaker and cover. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 08 - Electrical > 8A - Audio > Speaker > Installation > Installation. 9. Install door trim bolster. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 10. Repeat the lubrication process only on doors that have a regulator squeak or groan sound issue. REPAIR PROCEDURE - CS: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > 23-028-08 > Sep > 08 > Body - Noise When Operating Front/Rear Door Windows > Page 10317 1. Remove door trim panel and watershield to access regulator rails and sliders. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Removal > Removal. 2. Lower regulator to a position where forward (white) slider is visible through opening. 3. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 4. Move regulator to position where rear (white) slider is visible through opening. 5. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 6. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 7. Install watershield and door trim panel. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 8. Repeat the lubrication process only on doors that have a regulator squeak or groan issue. REPAIR PROCEDURE - LX: 1. Remove door trim panel and watershield to access regulator rails and sliders. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Removal > Removal. 2. Lower regulator to a position where forward (white) slider is visible through opening. 3. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 4. Move regulator to position where rear (white) slider is visible through opening. 5. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 6. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 7. Install watershield and door trim panel. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 8. Repeat the lubrication process only on doors that have a regulator squeak or groan issue. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > 23-028-08 > Sep > 08 > Body - Noise When Operating Front/Rear Door Windows > Page 10318 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > Page 10319 Rear Door Window Regulator: By Symptom Technical Service Bulletin # 23-028-08 Date: 080919 Body - Noise When Operating Front/Rear Door Windows NUMBER: 23-028-08 GROUP: Body DATE: September 19, 2008 SUBJECT: Squeak or Groan Sound When Raising or Lowering Door Glass OVERVIEW: This bulletin involves lubricating the window regulator rails. MODELS: 2006 - 2007 (CS) Pacifica 2007 - 2008 (LX) 300/Magnum/Charger 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber NOTE: This bulletin applies to all 2006 - 2007 CS, 2007 - 2008 LX vehicles built before November 14th, 2007 (MDH 1114XX) and PM/MK vehicles built before May 13th 2008 (MDH 0513XX). SYMPTOM/CONDITION: Squeak or squealing sound from window regulator area when raising or lowering front or rear door glass. Groaning sound when cycling front or rear door glass to full up position. DIAGNOSIS: If the customer describes the Symptom/Condition, verify the sound is from the regulator and is not being caused by glass run seals or belt seals. If the condition is present, perform the Repair Procedure on the door. PARTS REQUIRED: REPAIR PROCEDURE - PM/MK: 1. Remove door trim bolster. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > PANEL, Door Trim > Removal > REMOVAL. 2. Remove the door speaker cover and speaker. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 08 - Electrical > 8A - Audio > Speaker > Removal > Removal. 3. Lower regulator to a position where forward (white) slider is visible through opening. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > Page 10320 4. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers (Fig 1). 5. Move regulator to position where rear (white) slider is visible through opening. 6. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers (Fig 2). 7. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 8. Install the door speaker and cover. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 08 - Electrical > 8A - Audio > Speaker > Installation > Installation. 9. Install door trim bolster. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 10. Repeat the lubrication process only on doors that have a regulator squeak or groan sound issue. REPAIR PROCEDURE - CS: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > Page 10321 1. Remove door trim panel and watershield to access regulator rails and sliders. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Removal > Removal. 2. Lower regulator to a position where forward (white) slider is visible through opening. 3. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 4. Move regulator to position where rear (white) slider is visible through opening. 5. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 6. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 7. Install watershield and door trim panel. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 8. Repeat the lubrication process only on doors that have a regulator squeak or groan issue. REPAIR PROCEDURE - LX: 1. Remove door trim panel and watershield to access regulator rails and sliders. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Removal > Removal. 2. Lower regulator to a position where forward (white) slider is visible through opening. 3. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 4. Move regulator to position where rear (white) slider is visible through opening. 5. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 6. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 7. Install watershield and door trim panel. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 8. Repeat the lubrication process only on doors that have a regulator squeak or groan issue. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > Page 10322 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 23-028-08 Date: 080919 Body - Noise When Operating Front/Rear Door Windows NUMBER: 23-028-08 GROUP: Body DATE: September 19, 2008 SUBJECT: Squeak or Groan Sound When Raising or Lowering Door Glass OVERVIEW: This bulletin involves lubricating the window regulator rails. MODELS: 2006 - 2007 (CS) Pacifica 2007 - 2008 (LX) 300/Magnum/Charger 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber NOTE: This bulletin applies to all 2006 - 2007 CS, 2007 - 2008 LX vehicles built before November 14th, 2007 (MDH 1114XX) and PM/MK vehicles built before May 13th 2008 (MDH 0513XX). SYMPTOM/CONDITION: Squeak or squealing sound from window regulator area when raising or lowering front or rear door glass. Groaning sound when cycling front or rear door glass to full up position. DIAGNOSIS: If the customer describes the Symptom/Condition, verify the sound is from the regulator and is not being caused by glass run seals or belt seals. If the condition is present, perform the Repair Procedure on the door. PARTS REQUIRED: REPAIR PROCEDURE - PM/MK: 1. Remove door trim bolster. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > PANEL, Door Trim > Removal > REMOVAL. 2. Remove the door speaker cover and speaker. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 08 - Electrical > 8A - Audio > Speaker > Removal > Removal. 3. Lower regulator to a position where forward (white) slider is visible through opening. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > Page 10323 4. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers (Fig 1). 5. Move regulator to position where rear (white) slider is visible through opening. 6. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers (Fig 2). 7. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 8. Install the door speaker and cover. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 08 - Electrical > 8A - Audio > Speaker > Installation > Installation. 9. Install door trim bolster. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 10. Repeat the lubrication process only on doors that have a regulator squeak or groan sound issue. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > Page 10324 REPAIR PROCEDURE - CS: 1. Remove door trim panel and watershield to access regulator rails and sliders. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Removal > Removal. 2. Lower regulator to a position where forward (white) slider is visible through opening. 3. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 4. Move regulator to position where rear (white) slider is visible through opening. 5. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 6. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 7. Install watershield and door trim panel. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 8. Repeat the lubrication process only on doors that have a regulator squeak or groan issue. REPAIR PROCEDURE - LX: 1. Remove door trim panel and watershield to access regulator rails and sliders. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Removal > Removal. 2. Lower regulator to a position where forward (white) slider is visible through opening. 3. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 4. Move regulator to position where rear (white) slider is visible through opening. 5. Apply 0.5 oz. of white lithium grease pn 68003883AA to metal rail between slider fingers. 6. Raise and lower the window 3 or 4 times to distribute the grease and verify issue is resolved. 7. Install watershield and door trim panel. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - Body > Doors - Front/Rear > Panel, Door Trim > Installation > Installation. 8. Repeat the lubrication process only on doors that have a regulator squeak or groan issue. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > Page 10325 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Removal Rear Door Window Regulator: Service and Repair Removal REMOVAL 1. Remove door module. 2. Remove door glass (5). 3. Remove fasteners, wire connectors and remove window regulator (1) from door panel. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Removal > Page 10328 Rear Door Window Regulator: Service and Repair Installation INSTALLATION 1. Fasten window regulator to door panel. 2. Connect wire connectors. 3. Install glass ensuring proper seat. 4. Install door module. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Service and Repair > Removal Window Track: Service and Repair Removal REMOVAL 1. Remove door module. 2. Remove glass run fastener (2). 3. Remove glass run from door. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Service and Repair > Removal > Page 10333 Window Track: Service and Repair Installation INSTALLATION 1. Lower glass run into glass run door channel. 2. Install fastener (2). 3. Install door module. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Body - Windshield Crack Diagnosis Windshield: Technical Service Bulletins Body - Windshield Crack Diagnosis NUMBER: 23-047-06 GROUP: Body DATE: October 21, 2006 SUBJECT: Cracked Windshield MODELS: 2006 - 2007 (CS) Pacifica 2006 - 2007 (DC) Ram Cab & Chassis 2006 - 2007 (DR/DH/D1) Ram Truck 2006 - 2007 (HB) Durango 2007 (HG) Aspen 2006 (TJ) Wrangler/Wrangler Unlimited 2007 (JK) Wrangler/Wrangler Unlimited 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 2007 (KA) Nitro 2006 - 2007 (KJ) Liberty/Cherokee 2006 - 2007 (LE) 300C/300C Touring (International Market) 2006 - 2007 (LX) 300/Magnum/Charger 2007 (MK49) Compass 2006 - 2007 (ND) Dakota 2007 (PM) Caliber 2006 - 2007 (PT) Chrysler PT Cruiser 2006 - 2007 (RS) Town & Country/Caravan 2006 - 2007 (RG) Chrysler Voyager (International Market) 2006 - 2007 (WK) Grand Cherokee 2006 - 2007 (WH) Grand Cherokee (International Market) 2006 - 2007 (XK/XH) Commander 2006 (ZB) Viper 2006 - 2007 (ZH) Crossfire DISCUSSION: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Body - Windshield Crack Diagnosis > Page 10338 Windshield cracks caused by an impact from a foreign object; (i.e. stone) are often difficult to identify. The following assessment should be used to verify the presence of an impact chip on the crack. If no obvious impact chip is present, run a ball point pen along the crack and feel for a slight drop or pit in the glass. If a slight drop or pit in the glass is present, this indicates a small impact caused the crack. If the molding contains a witness mark or dent from an impact, inspect under the molding for an impact chip in the same manner. POLICY: Cracks caused by an impact are not warrantable. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 10339 Windshield: Service Precautions WINDSHIELD SAFETY PRECAUTIONS WARNING: Do not operate the vehicle within 24 hours of windshield installation. It takes at least 24 hours for urethane adhesive to cure. If it is not cured, the windshield may not perform properly in an accident. - Urethane adhesives are applied as a system. Use glass cleaner, glass prep solvent, glass primer, PVC (vinyl) primer and pinch weld (fence) primer provided by the adhesive manufacturer. If not, structural integrity could be compromised. - DaimlerChrysler does not recommend glass adhesive by brand. Technicians should review product labels and technical data sheets, and use only adhesives that their manufactures warrant will restore a vehicle to the requirements of FMVSS 212. Technicians should also insure that primers and cleaners are compatible with the particular adhesive used. - Be sure to refer to the urethane manufacturer's directions for curing time specifications, and do not use adhesive after its expiration date. - Vapors that are emitted from the urethane adhesive or primer could cause personal injury. Use them in a well-ventilated area. - Skin contact with urethane adhesive should be avoided. Personal injury may result. - Always wear eye and hand protection when working with glass. CAUTION: Protect all painted and trimmed surfaces from coming in contact with urethane or primers. Be careful not to damage painted surfaces when removing moldings or cutting urethane around windshield. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 10340 Windshield: Description and Operation DESCRIPTION The windshield is attached to the window frame (fence) with urethane adhesive. The urethane adhesive is applied cold and seals the surface area between the window opening and the glass. The primer adheres the urethane adhesive to the windshield. It is difficult to salvage a windshield during the removal operation. The windshield is part of the structural support for the roof. The urethane bonding used to secure the windshield to the fence is difficult to cut or clean from any surface. If the rubber seals are set in urethane, it would also be unlikely they could be salvaged. Before removing the windshield, check the availability of the windshield and seals from the parts supplier. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Removal Windshield: Service and Repair Removal REMOVAL 1. Before proceeding with the following repair procedure, review all warnings and cautions. Refer to Windows and Glass/Service Precautions. 2. Remove the rear view mirror. 3. Remove the cowl grille. CAUTION: Be careful not to damage painted surfaces when removing moldings or cutting urethane around the windshield. 4. Remove molding from the top of the windshield. 5. Using an assistant and a wire-type windshield cut-out tool (1, 3 and 4), cut and separate the urethane adhesive (2) securing the windshield to the windshield fence. 6. Carefully remove the windshield from the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Removal > Page 10343 Windshield: Service and Repair Installation INSTALLATION WARNING: Do not operate the vehicle within 24 hours of windshield installation. It takes at least 24 hours for urethane adhesive to cure. If it is not cured, the windshield may not perform properly if the vehicle is in an accident. CAUTION: To help prevent water leaks, partially roll down the left and right door glass before installing the windshield. This avoids pressurizing the passenger compartment if a door is slammed before the urethane is cured. CAUTION: Protect all painted and trimmed surfaces from coming in contact with urethane or primers. 1. If the windshield (1) is being reused, remove as much of the original urethane (3) as possible from the glass surface using a razor knife (2). NOTE: To prevent corrosion, do not damage paint on windshield fence when removing original urethane. NOTE: The windshield fence should be cleaned of most of its old urethane adhesive. A small amount of old urethane, approximately 1 mm (.04 in.) in height should remain on the fence. Do not completely remove all old urethane from the fence, the paint finish and bonding strength will be adversely affected. Support spacers located near the cowl at the bottom of the windshield fence should be replaced with new spacers. Replace any missing or damaged spacers around the perimeter of the windshield fence. 2. Using a razor knife (2), level the original bead of urethane (1) on the windshield fence (3) to a thickness of approximately 1 mm (0.04 in.) and remove any damaged adhesive backed spacers. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Removal > Page 10344 3. Install new adhesive backed spacers along the windshield fence as required. 4. Install a new rubber seal (2) along the top of the windshield (1). 5. Using an assistant, position the windshield into the windshield opening and against the windshield fence (3) and spacers. 6. Verify the windshield lays evenly against the fence at the top, bottom and sides of the opening. If not, the fence must be formed to the shape of the windshield. 7. Mark the windshield and the windshield fence with a grease pencil or pieces of masking tape to use as a reference for installation. 8. Using an assistant, remove the windshield from the windshield opening and place it on a suitable padded work surface. WARNING: Do not use solvent based glass cleaners to clean the windshield before applying glass prep and primer or poor glass adhesion may result. 9. Clean the inside of the windshield with an ammonia based glass cleaner and a lint-free cloth. 10. Apply glass prep adhesion promoter 25 mm (1 in.) wide (1) around the perimeter of the windshield (2) and 5 mm (0.2 in.) from the edge of the glass and wipe dry with a clean lint-free cloth until no streaks are visible. 11. Apply glass primer 25 mm (1 in.) wide (1) around the perimeter of the windshield (2) and 5 mm (0.2 in.) from the edge of the glass. Allow at least three minutes drying time. 12. Using a flashlight, verify that the primer is completely and evenly installed along the perimeter of the windshield. 13. Re-prime any area that is not fully and evenly primed. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Removal > Page 10345 14. Clean the windshield fence with an ammonia based glass cleaner and a lint-free cloth. 15. Apply pinch weld primer 15 mm (0.75 in.) wide (1) around the windshield fence (2). Allow at least three minutes drying time. 16. Using a flashlight, verify that the primer is completely and evenly installed along the windshield fence. 17. Re-prime any area that is not fully and evenly primed. CAUTION: Always apply the bead of adhesive to the windshield. Always install the windshield within 5 minutes after applying the adhesive. NOTE: If the original urethane adhesive has been exposed for more than 12 hours, the entire adhesive area will need to be re-primed prior to installing new adhesive. 18. Apply approximately a 10 mm (0.4 in.) wide bead of adhesive (1) with a triangular nozzle approximately 6 mm (0.230 in.) from the edge of the glass (2) starting at the bottom center of the windshield. 19. Run the end of the adhesive bead (1) on the windshield (2) parallel to the start of the bead and smooth the ends flush. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Removal > Page 10346 20. Using an assistant, position the windshield (1) over the windshield opening. 21. Using the grease pencil marks or tape as reference points, align the windshield to the windshield opening. 22. Carefully lower the windshield into the windshield opening. Guide the windshield and the rubber seal (2) at the top the windshield into its proper location. CAUTION: It is not possible to move the windshield after installation. The windshield should never be pressed into place by more than one person, because the windshield can break if pressed simultaneously on both sides. 23. Push the windshield inward until the windshield comes into contact with the spacers located on each side and the bottom of the windshield fence. 24. Install the cowl grill. 25. Install the rear view mirror onto the windshield. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Check Valve, Washer > Component Information > Technical Service Bulletins > Customer Interest for Check Valve: > 08-032-06A > Aug > 06 > Body - Water Marks On Rear Window Check Valve: Customer Interest Body - Water Marks On Rear Window NUMBER: 08-032-06 REV. A GROUP: Electrical DATE: August 8, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-032-06, DATED JULY 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF AN MODEL, REPAIR PROCEDURE AND NEW LABOR TIME. THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL AUGUST 21, 2006. SUBJECT: Water (Drip) Marks on Rear Window OVERVIEW: This bulletin involves installing a check valve in the rear wiper washer hose. MODELS: 2007 (PM) Caliber **2007 MK-49 Compass** NOTE: This bulletin applies to PM vehicles built before June 30, 2006 (MDH 0630XX) and **MK vehicles built before August 28, 2006 (MDH 0828xx)**. SYMPTOM/CONDITION: Water or drip marks may be visible on the rear window long after the rear washer system has not been in use. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE PM VEHICLES: 1. Using trim stick C-4755, pry the rear washer nozzle loose from the spoiler. NOTE: Secure the washer hose prior to cutting so it does not snap back into the spoiler during the next step. 2. While the washer nozzle is still attached to the hose pull out 26 mm (1 inch) of hose and cut it off. NOTE: Be sure to install the check valve correctly. The check valve has a arrows stamped on the shell that indicates fluid flow. The arrows need to point towards the rear nozzle. 3. Install check valve (68020654AA) into the cut end of the hose. If necessary apply a lubricant to the hose. 4. Install the washer nozzle and small piece of hose to the other end of the check valve. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Check Valve, Washer > Component Information > Technical Service Bulletins > Customer Interest for Check Valve: > 08-032-06A > Aug > 06 > Body - Water Marks On Rear Window > Page 10356 **REPAIR PROCEDURE MK-49 VEHICLES: 1. Remove the rear spoiler, using the procedures outlined in TechCONNECT 23-Body/Exterior/Rear - Spoiler - Removal. 2. Disconnect the rear washer hose from the feed to the in-line connector. 3. Measure 26 mm (1 inch) from the end of the hose and cut it off. NOTE: Be sure to install the check valve correctly. The check valve has a arrows stamped on the shell that indicates fluid flow. The arrows need to point towards the rear nozzle. 4. Install check valve (68020654AA) into the cut end of the hose. If necessary apply a lubricant to the hose. 5. Install the small hose to the other end of the in-line connector. CAUTION: Do not install the check valve between the in-line connector and the washer nozzle. 6. Install the rear spoiler, using the procedures outlined in TechCONNECT 23-Body/Exterior/Rear Spoiler - Installation. ** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Check Valve, Washer > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Check Valve: > 08-032-06A > Aug > 06 > Body - Water Marks On Rear Window Check Valve: All Technical Service Bulletins Body - Water Marks On Rear Window NUMBER: 08-032-06 REV. A GROUP: Electrical DATE: August 8, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-032-06, DATED JULY 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF AN MODEL, REPAIR PROCEDURE AND NEW LABOR TIME. THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL AUGUST 21, 2006. SUBJECT: Water (Drip) Marks on Rear Window OVERVIEW: This bulletin involves installing a check valve in the rear wiper washer hose. MODELS: 2007 (PM) Caliber **2007 MK-49 Compass** NOTE: This bulletin applies to PM vehicles built before June 30, 2006 (MDH 0630XX) and **MK vehicles built before August 28, 2006 (MDH 0828xx)**. SYMPTOM/CONDITION: Water or drip marks may be visible on the rear window long after the rear washer system has not been in use. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE PM VEHICLES: 1. Using trim stick C-4755, pry the rear washer nozzle loose from the spoiler. NOTE: Secure the washer hose prior to cutting so it does not snap back into the spoiler during the next step. 2. While the washer nozzle is still attached to the hose pull out 26 mm (1 inch) of hose and cut it off. NOTE: Be sure to install the check valve correctly. The check valve has a arrows stamped on the shell that indicates fluid flow. The arrows need to point towards the rear nozzle. 3. Install check valve (68020654AA) into the cut end of the hose. If necessary apply a lubricant to the hose. 4. Install the washer nozzle and small piece of hose to the other end of the check valve. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Check Valve, Washer > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Check Valve: > 08-032-06A > Aug > 06 > Body - Water Marks On Rear Window > Page 10362 **REPAIR PROCEDURE MK-49 VEHICLES: 1. Remove the rear spoiler, using the procedures outlined in TechCONNECT 23-Body/Exterior/Rear - Spoiler - Removal. 2. Disconnect the rear washer hose from the feed to the in-line connector. 3. Measure 26 mm (1 inch) from the end of the hose and cut it off. NOTE: Be sure to install the check valve correctly. The check valve has a arrows stamped on the shell that indicates fluid flow. The arrows need to point towards the rear nozzle. 4. Install check valve (68020654AA) into the cut end of the hose. If necessary apply a lubricant to the hose. 5. Install the small hose to the other end of the in-line connector. CAUTION: Do not install the check valve between the in-line connector and the washer nozzle. 6. Install the rear spoiler, using the procedures outlined in TechCONNECT 23-Body/Exterior/Rear Spoiler - Installation. ** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Check Valve, Washer > Component Information > Service and Repair > Removal Check Valve: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Partially remove the quarter trim from the right upper D-pillar (4). 3. Pull the headliner (5) away from the upper liftgate opening header (1) far enough to access and disconnect the liftgate washer supply hose (6) and the headliner washer supply hose (3) from the barbed nipple on each side of the check valve (2). 4. Remove the check valve. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Check Valve, Washer > Component Information > Service and Repair > Removal > Page 10365 Check Valve: Service and Repair Installation INSTALLATION 1. Position the rear check valve (2) between the upper liftgate opening header (1) and the headliner (5). Be certain that the raised arrow that indicates the flow direction on the center section of the valve is pointed toward the liftgate washer supply hose (6). 2. Reconnect the liftgate washer supply hose and the headliner washer supply hose (3) to the barbed nipples of the valve. 3. Reinstall the quarter trim onto the right upper D-pillar (4). 4. Reconnect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > System Information > Technical Service Bulletins > Customer Interest for Relays and Modules - Wiper and Washer Systems: > 08-027-06 > Jun > 06 > Wipers/Washers - Rear Wiper Inop./DTC's B231B & B2215 Relays and Modules - Wiper and Washer Systems: Customer Interest Wipers/Washers - Rear Wiper Inop./DTC's B231B & B2215 NUMBER: 08-027-06 GROUP: Electrical DATE: June 5, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: Flash - Rear Wiper Stops Operating with Diagnostic Trouble Codes B231B And B2215 OVERVIEW: This bulletin involves Flash Reprogramming the Totally Integrated Power Module (11PM) with updated software. MODELS: 2006 (PT) PT Cruiser 2007 (PM) Caliber NOTE: This bulletin applies to PM vehicles built before May 27, 2006 (MDH 0527XX) and all PT vehicles built before June 2, 2006 (MDH 0602XX) SYMPTOM/CONDITION: The rear wiper may stop operating. Upon further investigation the technician may find that the following Diagnostic Trouble Codes (DTC's) are present:: A. B2215 - FCM Internal B. B231B - Rear Wiper Motor Control Circuit Low DIAGNOSIS: 1. Connect the StarSCAN(R) to the vehicle. 2. Turn the ignition on. 3. With the Scan Tool, clear all TIPM DTC's. 4. Turn the Rear Windshield Wipers on. 5. Does the rear wiper operate? 6. Yes >> Perform the Repair Procedure. 7. No >> This bulletin does not apply, additional diagnosis is required. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > System Information > Technical Service Bulletins > Customer Interest for Relays and Modules - Wiper and Washer Systems: > 08-027-06 > Jun > 06 > Wipers/Washers - Rear Wiper Inop./DTC's B231B & B2215 > Page 10374 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 6.06 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old TIPM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the appropriate ECU in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash ECU" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Highlight the listed calibration. h. Select "Download to Scantool". i. Select "Close" after the download is complete, then select "Back". j. Highlight the listed calibration. k. Select "Update Controller". Follow on screen instructions. l. When the update is complete, select "OK". Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > System Information > Technical Service Bulletins > Customer Interest for Relays and Modules - Wiper and Washer Systems: > 08-027-06 > Jun > 06 > Wipers/Washers - Rear Wiper Inop./DTC's B231B & B2215 > Page 10375 m. Verify the part number at the top of the "Flash ECU" screen has updated to the new part number. NOTE: Due to the TIPM programming procedure, a DTC may be set in other modules (PCM, TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > System Information > Technical Service Bulletins > All Technical Service Bulletins for Relays and Modules - Wiper and Washer Systems: > 08-027-06 > Jun > 06 > Wipers/Washers - Rear Wiper Inop./DTC's B231B & B2215 Relays and Modules - Wiper and Washer Systems: All Technical Service Bulletins Wipers/Washers - Rear Wiper Inop./DTC's B231B & B2215 NUMBER: 08-027-06 GROUP: Electrical DATE: June 5, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: Flash - Rear Wiper Stops Operating with Diagnostic Trouble Codes B231B And B2215 OVERVIEW: This bulletin involves Flash Reprogramming the Totally Integrated Power Module (11PM) with updated software. MODELS: 2006 (PT) PT Cruiser 2007 (PM) Caliber NOTE: This bulletin applies to PM vehicles built before May 27, 2006 (MDH 0527XX) and all PT vehicles built before June 2, 2006 (MDH 0602XX) SYMPTOM/CONDITION: The rear wiper may stop operating. Upon further investigation the technician may find that the following Diagnostic Trouble Codes (DTC's) are present:: A. B2215 - FCM Internal B. B231B - Rear Wiper Motor Control Circuit Low DIAGNOSIS: 1. Connect the StarSCAN(R) to the vehicle. 2. Turn the ignition on. 3. With the Scan Tool, clear all TIPM DTC's. 4. Turn the Rear Windshield Wipers on. 5. Does the rear wiper operate? 6. Yes >> Perform the Repair Procedure. 7. No >> This bulletin does not apply, additional diagnosis is required. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > System Information > Technical Service Bulletins > All Technical Service Bulletins for Relays and Modules - Wiper and Washer Systems: > 08-027-06 > Jun > 06 > Wipers/Washers - Rear Wiper Inop./DTC's B231B & B2215 > Page 10381 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 6.06 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old TIPM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the appropriate ECU in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash ECU" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Highlight the listed calibration. h. Select "Download to Scantool". i. Select "Close" after the download is complete, then select "Back". j. Highlight the listed calibration. k. Select "Update Controller". Follow on screen instructions. l. When the update is complete, select "OK". Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > System Information > Technical Service Bulletins > All Technical Service Bulletins for Relays and Modules - Wiper and Washer Systems: > 08-027-06 > Jun > 06 > Wipers/Washers - Rear Wiper Inop./DTC's B231B & B2215 > Page 10382 m. Verify the part number at the top of the "Flash ECU" screen has updated to the new part number. NOTE: Due to the TIPM programming procedure, a DTC may be set in other modules (PCM, TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > System Information > Technical Service Bulletins > All Technical Service Bulletins for Relays and Modules - Wiper and Washer Systems: > Page 10383 Relays and Modules - Wiper and Washer Systems: By Symptom Technical Service Bulletin # 08-027-06 Date: 060605 Wipers/Washers - Rear Wiper Inop./DTC's B231B & B2215 NUMBER: 08-027-06 GROUP: Electrical DATE: June 5, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: Flash - Rear Wiper Stops Operating with Diagnostic Trouble Codes B231B And B2215 OVERVIEW: This bulletin involves Flash Reprogramming the Totally Integrated Power Module (11PM) with updated software. MODELS: 2006 (PT) PT Cruiser 2007 (PM) Caliber NOTE: This bulletin applies to PM vehicles built before May 27, 2006 (MDH 0527XX) and all PT vehicles built before June 2, 2006 (MDH 0602XX) SYMPTOM/CONDITION: The rear wiper may stop operating. Upon further investigation the technician may find that the following Diagnostic Trouble Codes (DTC's) are present:: A. B2215 - FCM Internal B. B231B - Rear Wiper Motor Control Circuit Low DIAGNOSIS: 1. Connect the StarSCAN(R) to the vehicle. 2. Turn the ignition on. 3. With the Scan Tool, clear all TIPM DTC's. 4. Turn the Rear Windshield Wipers on. 5. Does the rear wiper operate? 6. Yes >> Perform the Repair Procedure. 7. No >> This bulletin does not apply, additional diagnosis is required. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > System Information > Technical Service Bulletins > All Technical Service Bulletins for Relays and Modules - Wiper and Washer Systems: > Page 10384 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 6.06 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old TIPM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the appropriate ECU in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash ECU" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Highlight the listed calibration. h. Select "Download to Scantool". i. Select "Close" after the download is complete, then select "Back". j. Highlight the listed calibration. k. Select "Update Controller". Follow on screen instructions. l. When the update is complete, select "OK". Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > System Information > Technical Service Bulletins > All Technical Service Bulletins for Relays and Modules - Wiper and Washer Systems: > Page 10385 m. Verify the part number at the top of the "Flash ECU" screen has updated to the new part number. NOTE: Due to the TIPM programming procedure, a DTC may be set in other modules (PCM, TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 08-027-06 Date: 060605 Wipers/Washers - Rear Wiper Inop./DTC's B231B & B2215 NUMBER: 08-027-06 GROUP: Electrical DATE: June 5, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: Flash - Rear Wiper Stops Operating with Diagnostic Trouble Codes B231B And B2215 OVERVIEW: This bulletin involves Flash Reprogramming the Totally Integrated Power Module (11PM) with updated software. MODELS: 2006 (PT) PT Cruiser 2007 (PM) Caliber NOTE: This bulletin applies to PM vehicles built before May 27, 2006 (MDH 0527XX) and all PT vehicles built before June 2, 2006 (MDH 0602XX) SYMPTOM/CONDITION: The rear wiper may stop operating. Upon further investigation the technician may find that the following Diagnostic Trouble Codes (DTC's) are present:: A. B2215 - FCM Internal B. B231B - Rear Wiper Motor Control Circuit Low DIAGNOSIS: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > System Information > Technical Service Bulletins > All Technical Service Bulletins for Relays and Modules - Wiper and Washer Systems: > Page 10386 1. Connect the StarSCAN(R) to the vehicle. 2. Turn the ignition on. 3. With the Scan Tool, clear all TIPM DTC's. 4. Turn the Rear Windshield Wipers on. 5. Does the rear wiper operate? 6. Yes >> Perform the Repair Procedure. 7. No >> This bulletin does not apply, additional diagnosis is required. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 6.06 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old TIPM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the appropriate ECU in the list of modules. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > System Information > Technical Service Bulletins > All Technical Service Bulletins for Relays and Modules - Wiper and Washer Systems: > Page 10387 c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash ECU" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Highlight the listed calibration. h. Select "Download to Scantool". i. Select "Close" after the download is complete, then select "Back". j. Highlight the listed calibration. k. Select "Update Controller". Follow on screen instructions. l. When the update is complete, select "OK". m. Verify the part number at the top of the "Flash ECU" screen has updated to the new part number. NOTE: Due to the TIPM programming procedure, a DTC may be set in other modules (PCM, TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Description Wiper Switch: Description and Operation Description DESCRIPTION The right (wiper) multi-function switch is located on the right side of the steering column, just below the steering wheel. This switch is the primary control for the front and rear wiper and washer systems. The only visible components of the switch are the control stalk (1), control knob (2) and control sleeve (3) that extend through the steering column shrouds on the right side of the column. The remainder of the switch including its mounting provisions and electrical connection are concealed beneath the shrouds. The switch housing and controls (6) are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. A single screw (7) through a mounting tab integral to the back of the switch housing, and a slide tab integral to the bottom of the switch housing secure the switch to the mounting bracket integral to the clockspring (3). A single connector receptacle containing seven terminal pins is integral to the inboard end of the switch housing and is connected by a jumper wire harness (5) directly to the Steering Control Module (SCM), which is internal to the housing (2) of the left multi-function switch (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Description > Page 10393 The right (wiper) multi-function switch provides the vehicle operator with a control interface for the following wiper and washer system functions: - Continuous Front Wipers - The right multi-function switch control knob provides detent switching for two continuous front wipe modes, low speed or high speed. Intermittent Front Wipers - The right multi-function switch control knob provides detent switching for the intermittent front wipe mode with five minor detent delay interval positions. - Front Wiper Mist Mode - The right multi-function switch control stalk includes momentary switching of the front wiper motor low speed circuit to provide a mist mode features (sometimes referred to as pulse wipe), which allows the vehicle operator to momentarily operate the front wipers for one or more complete cycles. - Front Washer Mode - The right multi-function switch control stalk provides momentary switching for control of the front washer system operation. - Intermittent Rear Wipe Mode - The right multi-function switch control sleeve provides detent switching for a single fixed interval intermittent rear wiper mode. - Rear Washer Mode - The right multi-function switch control sleeve provides two momentary switch positions for control of rear washer system operation. The right multi-function switch cannot be adjusted or repaired. If any function of the switch is ineffective, or if the switch is damaged, the entire switch unit must be replaced. The clockspring (with the multi-function switch mounting bracket), the left multi-function switch (with the SCM), the right multi-function switch and the jumper wire harness are each available for separate service replacement. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Description > Page 10394 Wiper Switch: Description and Operation Operation OPERATION The right (wiper) multi-function switch uses a combination of resistor multiplexing and conventional switching to control the many functions and features it provides. The switch receives a clean ground from the Steering Control Module (SCM), then provides resistor multiplexed and conventional analog return outputs to the SCM to indicate the selected switch positions. The SCM then sends electronic switch status messages over a Local Interface Network (LIN) data bus to the Electromechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN), and the EMIC relays electronic wiper and washer switch request messages over the Controller Area Network (CAN) data bus to other electronic modules in the vehicle. If the SCM detects no inputs from the right multi-function switch, it transmits an electronic Signal Not Available (SNA) status message over the LIN data bus. The SNA status signals the EMIC to request other electronic modules to implement a failsafe mode of operation for the front and rear wiper systems. The failsafe mode will maintain the last selected front and rear wiper system operation for the remainder of the current ignition cycle, after which both wiper systems will default to OFF. The right multi-function switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, the most reliable, efficient and accurate means to diagnose this component requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Following are descriptions of how the right multi-function switch is operated to control the many front and rear wiper and washer system functions and features it provides: - Front Wiper Control - The control knob on the end of the right multi-function switch control stalk is rotated to one of the two continuous wiper detents, to one of five intermittent wiper detents, or to the OFF position to select the front wiper mode. The SCM reads the input from the right multi-function switch and sends electronic wiper switch status messages over the LIN data bus to the EMIC, which relays an electronic wiper switch request message over the CAN data bus to other electronic modules in the vehicle. - Front Wiper Mist Mode - The front wiper mist mode is requested when the right multi-function switch control stalk is depressed downward towards the floor to a momentary MIST position. The front wiper motor will continue to operate, one complete cycle at a time, for as long as the control stalk is held in this position. The SCM reads the resistor multiplexed input from the right multi-function switch and sends an electronic wiper switch status message over the LIN data bus to the EMIC, which relays an electronic wiper switch request message over the CAN data bus to other electronic modules in the vehicle. - Front Washer Control - The right multi-function switch control stalk is pulled rearward towards the steering wheel to a momentary WASH position to activate the washer pump/motor in the front washer mode. The washer pump/motor will continue to operate for as long as the control stalk is held in this position. The SCM reads the resistor multiplexed input from the right multi-function switch and sends an electronic washer switch status message over the LIN data bus to the EMIC, which relays an electronic washer switch request message over the CAN data bus to other electronic modules in the vehicle. - Rear Wiper Control - The rear wiper mode is selected when the right multi-function switch control sleeve is rotated to the fixed interval intermittent rear wipe detent position, or the OFF detent position. The SCM reads the input from the right multi-function switch and sends an electronic wiper switch status message over the LIN data bus to the EMIC, which relays an electronic wiper switch request message over the CAN data bus to other electronic modules in the vehicle. - Rear Washer Control - The right multi-function switch control sleeve is rotated to one of two momentary WASH positions, either fully forward or fully rearward, to activate the washer pump/motor in the rear washer mode. The washer pump/motor will continue to operate in the rear washer mode until the control sleeve is released. The SCM reads the input from the right multi-function switch and sends an electronic washer switch status message over the LIN data bus to the EMIC, which relays an electronic washer switch request message over the CAN data bus to other electronic modules in the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 10395 Wiper Switch: Testing and Inspection RIGHT MULTI-FUNCTION SWITCH WARNING: To avoid personal injury or death, on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, occupant classification system, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. The right multi-function switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the Steering Control Module (SCM) or the electronic controls or communication between other modules and devices that provide some features of the front and rear wiper and washer systems. The most reliable, efficient and accurate means to diagnose the SCM or the electronic controls and communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. 1. Remove the right multi-function switch from the integral mounting bracket on the right side of the clockspring. 2. Using an ohmmeter, test the resistance between the terminals of the switch as shown in the three Function Tests tables. For all functions except those of the control stalk the values should be either less than 100 ohms (switch CLOSED) or greater than 1 megohm (switch OPEN). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 10396 3. If the switch fails any of the tests, replace the ineffective right multi-function switch as required. If the switch tests okay, but the switch input to the Steering Control Module (SCM) remains incorrect, be certain to check for a short or open in the jumper harness between the right multi-function switch and the SCM. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Removal Wiper Switch: Service and Repair Removal REMOVAL WARNING: To avoid personal injury or death, on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, occupant classification system, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove both the upper and lower shrouds from the steering column. 3. Remove the screw (2) that secures the right multi-function switch (1) to the mounting bracket integral to the right side of the clockspring (3) on the steering column. 4. Slide the switch away from the clockspring far enough to disengage the slide tab on the bottom of the switch housing from the channel formation in the mounting bracket. 5. Disconnect the jumper wire harness connector (1) from the connector receptacle on the inboard end of the right multi-function switch (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Removal > Page 10399 6. Remove the switch from the clockspring (3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Removal > Page 10400 Wiper Switch: Service and Repair Installation INSTALLATION WARNING: To avoid personal injury or death, on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, occupant classification system, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the right multi-function switch (2) close enough to the mounting bracket (3) integral to the right side of the clockspring to reconnect the jumper wire harness connector (1) to the connector receptacle on the inboard side of the switch housing. 2. Align the slide tab on the bottom of the switch housing with the channel integral to the clockspring mounting bracket, then slide the switch into the bracket until it is firmly seated. 3. Install and tighten the screw (2) that secures the mounting tab on the back of the right multi-function switch (1) to the mounting bracket on the clockspring (3). 4. Reinstall the upper and lower shrouds onto the steering column. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Removal > Page 10401 5. Reconnect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Technical Service Bulletins > Customer Interest for Windshield Washer Hose: > 08-032-06A > Aug > 06 > Body - Water Marks On Rear Window Windshield Washer Hose: Customer Interest Body - Water Marks On Rear Window NUMBER: 08-032-06 REV. A GROUP: Electrical DATE: August 8, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-032-06, DATED JULY 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF AN MODEL, REPAIR PROCEDURE AND NEW LABOR TIME. THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL AUGUST 21, 2006. SUBJECT: Water (Drip) Marks on Rear Window OVERVIEW: This bulletin involves installing a check valve in the rear wiper washer hose. MODELS: 2007 (PM) Caliber **2007 MK-49 Compass** NOTE: This bulletin applies to PM vehicles built before June 30, 2006 (MDH 0630XX) and **MK vehicles built before August 28, 2006 (MDH 0828xx)**. SYMPTOM/CONDITION: Water or drip marks may be visible on the rear window long after the rear washer system has not been in use. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE PM VEHICLES: 1. Using trim stick C-4755, pry the rear washer nozzle loose from the spoiler. NOTE: Secure the washer hose prior to cutting so it does not snap back into the spoiler during the next step. 2. While the washer nozzle is still attached to the hose pull out 26 mm (1 inch) of hose and cut it off. NOTE: Be sure to install the check valve correctly. The check valve has a arrows stamped on the shell that indicates fluid flow. The arrows need to point towards the rear nozzle. 3. Install check valve (68020654AA) into the cut end of the hose. If necessary apply a lubricant to the hose. 4. Install the washer nozzle and small piece of hose to the other end of the check valve. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Technical Service Bulletins > Customer Interest for Windshield Washer Hose: > 08-032-06A > Aug > 06 > Body - Water Marks On Rear Window > Page 10410 **REPAIR PROCEDURE MK-49 VEHICLES: 1. Remove the rear spoiler, using the procedures outlined in TechCONNECT 23-Body/Exterior/Rear - Spoiler - Removal. 2. Disconnect the rear washer hose from the feed to the in-line connector. 3. Measure 26 mm (1 inch) from the end of the hose and cut it off. NOTE: Be sure to install the check valve correctly. The check valve has a arrows stamped on the shell that indicates fluid flow. The arrows need to point towards the rear nozzle. 4. Install check valve (68020654AA) into the cut end of the hose. If necessary apply a lubricant to the hose. 5. Install the small hose to the other end of the in-line connector. CAUTION: Do not install the check valve between the in-line connector and the washer nozzle. 6. Install the rear spoiler, using the procedures outlined in TechCONNECT 23-Body/Exterior/Rear Spoiler - Installation. ** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield Washer Hose: > 08-032-06A > Aug > 06 > Body - Water Marks On Rear Window Windshield Washer Hose: All Technical Service Bulletins Body - Water Marks On Rear Window NUMBER: 08-032-06 REV. A GROUP: Electrical DATE: August 8, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-032-06, DATED JULY 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF AN MODEL, REPAIR PROCEDURE AND NEW LABOR TIME. THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL AUGUST 21, 2006. SUBJECT: Water (Drip) Marks on Rear Window OVERVIEW: This bulletin involves installing a check valve in the rear wiper washer hose. MODELS: 2007 (PM) Caliber **2007 MK-49 Compass** NOTE: This bulletin applies to PM vehicles built before June 30, 2006 (MDH 0630XX) and **MK vehicles built before August 28, 2006 (MDH 0828xx)**. SYMPTOM/CONDITION: Water or drip marks may be visible on the rear window long after the rear washer system has not been in use. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE PM VEHICLES: 1. Using trim stick C-4755, pry the rear washer nozzle loose from the spoiler. NOTE: Secure the washer hose prior to cutting so it does not snap back into the spoiler during the next step. 2. While the washer nozzle is still attached to the hose pull out 26 mm (1 inch) of hose and cut it off. NOTE: Be sure to install the check valve correctly. The check valve has a arrows stamped on the shell that indicates fluid flow. The arrows need to point towards the rear nozzle. 3. Install check valve (68020654AA) into the cut end of the hose. If necessary apply a lubricant to the hose. 4. Install the washer nozzle and small piece of hose to the other end of the check valve. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield Washer Hose: > 08-032-06A > Aug > 06 > Body - Water Marks On Rear Window > Page 10416 **REPAIR PROCEDURE MK-49 VEHICLES: 1. Remove the rear spoiler, using the procedures outlined in TechCONNECT 23-Body/Exterior/Rear - Spoiler - Removal. 2. Disconnect the rear washer hose from the feed to the in-line connector. 3. Measure 26 mm (1 inch) from the end of the hose and cut it off. NOTE: Be sure to install the check valve correctly. The check valve has a arrows stamped on the shell that indicates fluid flow. The arrows need to point towards the rear nozzle. 4. Install check valve (68020654AA) into the cut end of the hose. If necessary apply a lubricant to the hose. 5. Install the small hose to the other end of the in-line connector. CAUTION: Do not install the check valve between the in-line connector and the washer nozzle. 6. Install the rear spoiler, using the procedures outlined in TechCONNECT 23-Body/Exterior/Rear Spoiler - Installation. ** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations Windshield Washer Pump: Locations Component ID: 177 Component : PUMP-WASHER-WINDSHIELD Connector: Name : PUMP-WASHER-WINDSHIELD Color : BLACK # of pins : 2 Pin Description Circuit 1 REAR WASHER PUMP MOTOR CONTROL W20 20BR/YL 2 FRONT WASHER PUMP MOTOR CONTROL W10 20BR/TN Component Location - 2 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 10420 Component Location - 4 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 10421 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 10422 Windshield Washer Pump: Diagrams Component ID: 177 Component : PUMP-WASHER-WINDSHIELD Connector: Name : PUMP-WASHER-WINDSHIELD Color : BLACK # of pins : 2 Pin Description Circuit 1 REAR WASHER PUMP MOTOR CONTROL W20 20BR/YL 2 FRONT WASHER PUMP MOTOR CONTROL W10 20BR/TN Component Location - 2 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 10423 Component Location - 4 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 10424 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Description and Operation > Description Windshield Washer Pump: Description and Operation Description DESCRIPTION The washer pump/motor unit is located on the top of a sump area of the washer reservoir, on the forward side of the reservoir ahead of the right front strut tower in the engine compartment. A small permanently lubricated and sealed reversible electric motor (3) is coupled to the rotor-type washer pump (4). The use of an integral valve body (7) allows the washer pump/motor unit to provide washer fluid to either the front or the rear washer systems, depending upon the direction of the motor/pump impeller rotation. An inlet nipple (6) on the pump housing passes through a rubber grommet seal/filter screen installed in a dedicated mounting hole of the washer reservoir sump. The filter screen prevents most debris from entering the pump housing. When the pump is installed in the reservoir the one barbed outlet nipple (5 and 8) on the pump valve body housing connects the unit to the front washer hose, and the other barbed outlet nipple connects the unit to the rear washer hose. The washer pump/motor unit is retained on the reservoir by the interference fit between the pump inlet nipple and the grommet seal, which is a light press fit that allows for mounting of the washer pump without the use of fasteners. An integral connector receptacle (1) on the top of the motor housing connects the unit to the vehicle electrical system through a dedicated take out and connector of the engine compartment wire harness. The washer pump/motor unit cannot be repaired. If ineffective or damaged, the entire washer pump/motor unit must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Description and Operation > Description > Page 10427 Windshield Washer Pump: Description and Operation Operation OPERATION The washer pump/motor unit features a reversible electric motor. The direction of the motor is controlled by hard wired outputs from the Totally Integrated Power Module (TIPM). When battery current and ground are applied to the two pump motor terminals, the motor rotates in one direction. When the polarity of these connections is reversed, the motor rotates in the opposite direction. When the pump motor is energized, the rotor-type pump pressurizes the washer fluid and forces it through one of the two pump outlet nipples, and into the front or rear washer plumbing. The TIPM controls the hard wired outputs to the pump motor based upon electronic washer request messages received over the Controller Area Network (CAN) data bus from the Electromechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). The EMIC receives electronic washer switch status messages over a Local Interface Network (LIN) bus connection from the Steering Control Module (SCM) within the left (lighting) multi-function switch housing. The SCM monitors hard wired analog and multiplex inputs from the washer switch circuitry contained within the right (wiper) multi-function switch to determine the proper electronic messages to send. Washer fluid is drawn through the pump inlet nipple from the washer reservoir to the inlet port of the washer pump housing. An integral valve body is located in a housing on the outlet port side (2) of the pump housing. A diaphragm (4) in this valve body controls which washer system plumbing receives the washer fluid being pressurized by the pump. When the pump impeller (1) rotates in the counterclockwise direction (viewed from the bottom), the biased diaphragm is sealing off the rear washer system outlet and nipple so the pressurized washer fluid is pushed out through the pump front outlet port and the front washer outlet nipple (5). When the pump impeller rotates in the clockwise direction (viewed from the bottom), pressurized washer fluid is pushed out through the pump rear outlet port and moves the diaphragm to open the rear washer outlet nipple and seal off the front washer outlet nipple, then the pressurized washer fluid is pushed out through the rear washer outlet nipple (3). The washer pump/motor unit and the hard wired motor control circuits from the TIPM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the washer pump/motor unit or the electronic controls or communication between other modules and devices that provide some features of the front and rear wiper and washer system. The most reliable, efficient, and accurate means to diagnose the washer pump/motor unit or the electronic controls and communication related to washer pump/motor unit operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair > Removal Windshield Washer Pump: Service and Repair Removal REMOVAL NOTE: The washer pump/motor can be removed from the washer reservoir without removing the reservoir from the vehicle. 1. Disconnect and isolate the battery negative cable. 2. Siphon the washer fluid from the washer reservoir (1) into a clean container for reuse. 3. Disconnect the engine compartment wire harness connector (2) from the washer pump/motor unit (3) connector receptacle on the top of the motor housing. 4. Disconnect the two washer hoses (4 and 5) from the two washer pump/motor unit outlet nipples. 5. Pull the washer pump/motor unit straight up and out of the washer reservoir far enough to disengage the inlet nipple from the rubber grommet seal/filter screen in the reservoir. Care must be taken not to damage the reservoir. 6. Remove the rubber grommet seal/filter screen for the washer pump from the pump mounting hole in the washer reservoir and discard. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair > Removal > Page 10430 Windshield Washer Pump: Service and Repair Installation INSTALLATION 1. Install a new rubber grommet seal/filter screen unit into the washer pump mounting hole in the washer reservoir (1). Always use a new rubber grommet seal/filter screen on the reservoir. 2. Position the inlet nipple of the washer pump (3) to the rubber grommet seal/filter screen in the washer reservoir. 3. Using hand pressure, press firmly and evenly downward on the washer pump/motor unit until the inlet nipple is fully seated in the rubber grommet seal/filter screen in the pump mounting hole of the reservoir. 4. Reconnect the two washer hoses (4 and 5) to the two barbed pump outlet nipples. Be certain that the hose in the trough on the outboard side of the reservoir is connected to the rear (black) nipple, and the hose on the inboard side of the reservoir is connected to the front (white) nipple. 5. Reconnect the engine compartment wire harness connector (2) for the washer pump/motor unit to the connector receptacle on the top of the motor housing. 6. Reconnect the battery negative cable. 7. Refill the washer reservoir with the washer fluid siphoned from the reservoir during the removal procedure. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Description and Operation > Description Windshield Washer Reservoir: Description and Operation Description DESCRIPTION A single washer fluid reservoir (2) is used for both the front and rear washer systems. The molded plastic washer fluid reservoir is mounted on the forward side of the right front strut tower and wheel house in the engine compartment. The filler neck extends upward into the engine compartment and a single screw installed through a mounting tab (7) on the back of the filler neck secures the unit to a stamped metal bracket on the front of the strut tower. A bright yellow plastic filler cap (1) with an International Control and Display Symbol icon for Windshield Washer molded into it snaps over the open end of the filler neck. The cap hinges on and is secured to a molded-in hook formation on the top of the mounting tab on the filler neck. There is a dedicated hole in the sump area at the lower front end of the reservoir provided for the washer pump/motor unit (5). The outboard side of the washer reservoir has an integral clip (4) and two integral troughs (6) through which the washer hoses are routed from the washer pump up into the engine compartment. An integral mounting post on the bottom of the reservoir is inserted into a hole in the horizontal front extension of the fender wheel house to locate and secure the lower end of the reservoir. An integral latch tab (3) on the upper outboard side of the reservoir engages a slot in the inboard side of the coolant reserve container (gasoline engine) or coolant pressure container (diesel engine) to aid in mounting that unit in the engine compartment. The coolant reserve container or coolant pressure container must be dismounted, but need not be removed to access the washer reservoir for service. The washer reservoir cannot be repaired and, if ineffective or damaged, it must be replaced. The washer reservoir, rubber grommet seal/filter screen for the washer pump/motor unit and the filler cap are each available for individual service replacement. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Description and Operation > Description > Page 10435 Windshield Washer Reservoir: Description and Operation Operation OPERATION The washer fluid reservoir provides a secure, on-vehicle storage location for a large reserve of washer fluid for operation of the front and rear washer systems. The washer reservoir filler cap provides a clearly marked and readily accessible point from which to add washer fluid to the reservoir. The washer pump/motor unit is located in a sump area near the lower forward side of the reservoir to be certain that washer fluid will be available to the pump as the fluid level in the reservoir becomes depleted. The washer pump/motor unit is mounted in the lowest position in the sump. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Removal Windshield Washer Reservoir: Service and Repair Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove or disengage each of the fasteners that secure the coolant reserve container (gasoline engine) or the coolant pressure container (diesel engine) to the inboard side of the washer reservoir and move the container aside as necessary to gain access to the washer reservoir for removal. Refer to COOLING/ENGINE System for the appropriate procedures for the engine and coolant container type as the vehicle is equipped. 3. Siphon the washer fluid from the washer reservoir (1) into a clean container for reuse. 4. Disconnect the engine compartment wire harness connector (7) from the washer pump/motor. NOTE: To aid in reinstallation, note the installed position of the washer hoses prior to disconnecting them. 5. Disconnect the front and rear washer hoses (3) from the reservoir washer hoses near the top of the right front strut tower. 6. Remove the screw (2) that secures the mounting tab on the back of the reservoir filler neck to the bracket (4) on the forward side of the right front strut tower. 7. Pull the washer reservoir upward far enough to disengage the post (5) on the underside of the reservoir from the hole in the horizontal extension of the right front wheel house (6). 8. Remove the washer reservoir from the engine compartment. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Removal > Page 10438 Windshield Washer Reservoir: Service and Repair Installation INSTALLATION 1. Position the washer reservoir (1) into the right front corner of the engine compartment. 2. Align and engage the post (5) on the underside of the reservoir into the hole in the horizontal extension of the right front wheel house (6). 3. Install and tighten the screw (2) that secures the mounting tab on the back of the reservoir filler neck to the bracket (4) on the forward side of the right front strut tower. NOTE: Be certain to reconnect the front and rear washer hoses to the proper reservoir hoses from the washer pump. Failure to properly connect the hoses will cause the front and rear washer systems to operate incorrectly. 4. Reconnect the front and rear washer hoses (3) to the reservoir washer hoses near the top of the right front strut tower. 5. Reconnect the headlamp and dash wire harness connector (7) to the washer pump/motor unit. 6. Position the coolant reserve container (gasoline engine) or the coolant pressure container (diesel engine) to the inboard side of the washer reservoir and reinstall or engage each of the fasteners that secure the container. Refer to COOLING/ENGINE System for the appropriate procedures for the engine and coolant container type as the vehicle is equipped. 7. Refill the washer reservoir with the washer fluid drained during removal. 8. Reconnect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Technical Service Bulletins > Customer Interest for Windshield Washer Spray Nozzle: > 08-032-06A > Aug > 06 > Body Water Marks On Rear Window Windshield Washer Spray Nozzle: Customer Interest Body - Water Marks On Rear Window NUMBER: 08-032-06 REV. A GROUP: Electrical DATE: August 8, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-032-06, DATED JULY 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF AN MODEL, REPAIR PROCEDURE AND NEW LABOR TIME. THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL AUGUST 21, 2006. SUBJECT: Water (Drip) Marks on Rear Window OVERVIEW: This bulletin involves installing a check valve in the rear wiper washer hose. MODELS: 2007 (PM) Caliber **2007 MK-49 Compass** NOTE: This bulletin applies to PM vehicles built before June 30, 2006 (MDH 0630XX) and **MK vehicles built before August 28, 2006 (MDH 0828xx)**. SYMPTOM/CONDITION: Water or drip marks may be visible on the rear window long after the rear washer system has not been in use. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE PM VEHICLES: 1. Using trim stick C-4755, pry the rear washer nozzle loose from the spoiler. NOTE: Secure the washer hose prior to cutting so it does not snap back into the spoiler during the next step. 2. While the washer nozzle is still attached to the hose pull out 26 mm (1 inch) of hose and cut it off. NOTE: Be sure to install the check valve correctly. The check valve has a arrows stamped on the shell that indicates fluid flow. The arrows need to point towards the rear nozzle. 3. Install check valve (68020654AA) into the cut end of the hose. If necessary apply a lubricant to the hose. 4. Install the washer nozzle and small piece of hose to the other end of the check valve. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Technical Service Bulletins > Customer Interest for Windshield Washer Spray Nozzle: > 08-032-06A > Aug > 06 > Body Water Marks On Rear Window > Page 10447 **REPAIR PROCEDURE MK-49 VEHICLES: 1. Remove the rear spoiler, using the procedures outlined in TechCONNECT 23-Body/Exterior/Rear - Spoiler - Removal. 2. Disconnect the rear washer hose from the feed to the in-line connector. 3. Measure 26 mm (1 inch) from the end of the hose and cut it off. NOTE: Be sure to install the check valve correctly. The check valve has a arrows stamped on the shell that indicates fluid flow. The arrows need to point towards the rear nozzle. 4. Install check valve (68020654AA) into the cut end of the hose. If necessary apply a lubricant to the hose. 5. Install the small hose to the other end of the in-line connector. CAUTION: Do not install the check valve between the in-line connector and the washer nozzle. 6. Install the rear spoiler, using the procedures outlined in TechCONNECT 23-Body/Exterior/Rear Spoiler - Installation. ** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield Washer Spray Nozzle: > 08-032-06A > Aug > 06 > Body - Water Marks On Rear Window Windshield Washer Spray Nozzle: All Technical Service Bulletins Body - Water Marks On Rear Window NUMBER: 08-032-06 REV. A GROUP: Electrical DATE: August 8, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-032-06, DATED JULY 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF AN MODEL, REPAIR PROCEDURE AND NEW LABOR TIME. THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL AUGUST 21, 2006. SUBJECT: Water (Drip) Marks on Rear Window OVERVIEW: This bulletin involves installing a check valve in the rear wiper washer hose. MODELS: 2007 (PM) Caliber **2007 MK-49 Compass** NOTE: This bulletin applies to PM vehicles built before June 30, 2006 (MDH 0630XX) and **MK vehicles built before August 28, 2006 (MDH 0828xx)**. SYMPTOM/CONDITION: Water or drip marks may be visible on the rear window long after the rear washer system has not been in use. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE PM VEHICLES: 1. Using trim stick C-4755, pry the rear washer nozzle loose from the spoiler. NOTE: Secure the washer hose prior to cutting so it does not snap back into the spoiler during the next step. 2. While the washer nozzle is still attached to the hose pull out 26 mm (1 inch) of hose and cut it off. NOTE: Be sure to install the check valve correctly. The check valve has a arrows stamped on the shell that indicates fluid flow. The arrows need to point towards the rear nozzle. 3. Install check valve (68020654AA) into the cut end of the hose. If necessary apply a lubricant to the hose. 4. Install the washer nozzle and small piece of hose to the other end of the check valve. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield Washer Spray Nozzle: > 08-032-06A > Aug > 06 > Body - Water Marks On Rear Window > Page 10453 **REPAIR PROCEDURE MK-49 VEHICLES: 1. Remove the rear spoiler, using the procedures outlined in TechCONNECT 23-Body/Exterior/Rear - Spoiler - Removal. 2. Disconnect the rear washer hose from the feed to the in-line connector. 3. Measure 26 mm (1 inch) from the end of the hose and cut it off. NOTE: Be sure to install the check valve correctly. The check valve has a arrows stamped on the shell that indicates fluid flow. The arrows need to point towards the rear nozzle. 4. Install check valve (68020654AA) into the cut end of the hose. If necessary apply a lubricant to the hose. 5. Install the small hose to the other end of the in-line connector. CAUTION: Do not install the check valve between the in-line connector and the washer nozzle. 6. Install the rear spoiler, using the procedures outlined in TechCONNECT 23-Body/Exterior/Rear Spoiler - Installation. ** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Description and Operation > Description Windshield Washer Spray Nozzle: Description and Operation Description Front FRONT The fluidic front washer nozzles (2) are constructed of molded plastic and include an integral check valve. Each nozzle has two integral latches (3) that secure them in dedicated holes in the hood panel near the base of the windshield. The domed upper surface of the washer nozzle is visible on the outside of the hood panel, and the two nozzle orifices (1) are oriented towards the windshield glass. An integral diaphragm type check valve is contained within the body of each nozzle. The washer plumbing fittings (4) for the washer nozzles extend below the hood panel and are accessible from the engine compartment. The front washer nozzles cannot be adjusted or repaired and, if ineffective or damaged, they must be replaced. Rear REAR The fluidic rear washer nozzle is constructed of molded plastic. The rear washer nozzle is secured by two integral latch features (1) within a mounting hole to the right of the Center High-Mounted Stop Lamp (CHMSL) in the lower surface of the rear spoiler above the liftgate glass opening on the outer liftgate panel. The outer surface of the washer nozzle is visible on the lower exterior surface of the spoiler, and a rubber gasket (3) seals the nozzle to the spoiler mounting hole. The nozzle orifice (4) is oriented downward towards the liftgate glass. The washer plumbing fitting (2) is concealed between the spoiler and the liftgate outer panel. The rear washer nozzle cannot be adjusted or repaired and, if ineffective or damaged, it must be replaced. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Description and Operation > Description > Page 10456 Windshield Washer Spray Nozzle: Description and Operation Operation Front FRONT The two front washer nozzles are designed to dispense washer fluid into the wiper pattern area on the outside of the windshield glass. Pressurized washer fluid is fed to each nozzle from the washer reservoir by the washer pump/motor unit through a single hose, which is attached to a barbed nipple on each washer nozzle below the inner hood panel. A fluidic matrix within the washer nozzle causes the pressurized washer fluid to be emitted from the nozzle orifice as an oscillating stream to more effectively cover a larger area of the glass to be cleaned. The integral check valve in each nozzle prevents washer fluid from draining out of the washer supply hoses back to the washer reservoir. This drain-back would result in a lengthy delay after the washer switch is actuated until washer fluid was dispensed through the nozzles, because the washer pump would have to refill the washer plumbing from the reservoir to the nozzles. Such a drain-back condition could also result in water, dirt, or other outside contaminants being siphoned into the washer system through the washer nozzle orifice. This water could subsequently freeze and plug the nozzle, while other contaminants could interfere with proper nozzle operation and cause improper nozzle spray patterns. In addition, the check valve prevents washer fluid from siphoning through the washer nozzles after the washer system is turned OFF. When the washer pump pressurizes and pumps washer fluid from the reservoir through the washer plumbing, the fluid pressure unseats a diaphragm from over a sump well within the nozzle by overriding the spring pressure applied to it by a piston. With the diaphragm unseated, washer fluid is allowed to flow toward the nozzle orifice. When the washer pump stops operating, the spring pressure on the piston seats the diaphragm over the sump well in the nozzle and fluid flow in either direction within the washer plumbing is prevented. Rear REAR The rear washer nozzle is designed to dispense washer fluid into the wiper pattern area on the outside of the liftgate glass. Pressurized washer fluid is fed to the nozzle from the washer reservoir by the washer pump/motor through a single hose, which is attached to a barbed nipple on the back of the nozzle. A fluidic matrix within the nozzle causes the pressurized washer fluid to be emitted from the nozzle orifice as an oscillating stream to more effectively cover a larger area of the glass to be cleaned. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Service and Repair > Removal Windshield Washer Spray Nozzle: Service and Repair Removal Front FRONT 1. From the underside of the hood, disengage the rear edge of the silencer pad from the tabs that secure it to the inner hood reinforcement (1) as necessary to access the front washer nozzle hose connections (2). 2. Disconnect the hose connection from the barbed nipple of the front washer nozzle. 3. From the underside of the hood, release the integral latches of the front washer nozzle (2) and push the nozzle out through the mounting hole toward the top side of the hood (1). 4. Remove the nozzle from the top of the hood panel. Rear REAR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Service and Repair > Removal > Page 10459 1. Disconnect and isolate the battery negative cable. 2. Remove the fasteners that secure the spoiler (3) to the liftgate outer panel (1). 3. Pull the spoiler away from the liftgate far enough to access and disconnect the liftgate washer supply hose (2) from the barbed nipple on the back of the rear washer nozzle (4). 4. From the back of the spoiler, depress the two integral latch features of the nozzle, while pulling the nozzle out through the face of the spoiler. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Service and Repair > Removal > Page 10460 Windshield Washer Spray Nozzle: Service and Repair Installation Front FRONT 1. Position the front washer nozzle (2) to the mounting hole on the outside of the hood panel (1). 2. Align the anti-rotation tab of the nozzle with the anti-rotation notch in the mounting hole. 3. Using hand pressure, push firmly and evenly on the top of the nozzle until the integral latches lock into place on the underside of the hood. 4. From the underside of the hood, reconnect the washer hose connector (2) to the barbed nipple of the nozzle. 5. Reinstall the rear edge of the hood silencer pad to the clips on the inner hood reinforcement (1). Rear REAR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Service and Repair > Removal > Page 10461 1. Position the rear washer nozzle (4) through the mounting hole from the face of the liftgate spoiler (3). 2. Using hand pressure, press the nozzle firmly and evenly into the mounting hole until the two integral latch features are fully engaged on the back of the spoiler. 3. From the back of the spoiler, reconnect the liftgate washer supply hose (2) to the barbed nipple of the nozzle. 4. Reinstall the spoiler onto the liftgate outer panel (1). 5. Reconnect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Technical Service Bulletins > Body - Rear Wiper Arm Loose Wiper Arm: Technical Service Bulletins Body - Rear Wiper Arm Loose NUMBER: 23-053-06 GROUP: Body DATE: December 1, 2006 SUBJECT: Rear Wiper Arm Loose OVERVIEW: This bulletin involves installing a new nut on the rear wiper arm. MODELS: 2007 (MK-49) Compass 2007 (PM) Caliber NOTE: This bulletin applies to vehicles built before November 21, 2006 (MDH 1120XX). SYMPTOM/CONDITION: The rear wiper arm may come loose after use. DIAGNOSIS: If the vehicle operator describes the above Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Technical Service Bulletins > Body - Rear Wiper Arm Loose > Page 10466 1. Following the procedures outlined in TechCONNECT, 8 - Electrical/Wipers/Washers/Wiper Arms - Installation replace the rear wiper arm nut (p/n 06104715AA) and tighten the nut to 10 N.m +/-1 N.m (7 ft. lbs.) (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Removal Wiper Arm: Service and Repair Removal Front FRONT 1. Lift the front wiper arm (2) to its over-center position to hold the wiper blade (1) off of the glass and relieve the spring tension on the wiper arm to pivot shaft connection. 2. Carefully pry the plastic nut cap (4) off of the pivot end of the wiper arm. 3. Remove the nut (3) that secures the wiper arm to the wiper pivot shaft (5). CAUTION: The use of a battery terminal puller when removing the front wiper arm is NOT recommended as this may damage the front wiper arm. 4. Use a slight rocking action to disengage the front wiper arm pivot end from the pivot shaft and remove the wiper arm. Rear REAR 1. Lift the rear wiper arm (3) to hold the wiper blade (5) off of the glass and relieve the spring tension on the wiper arm to output shaft connection. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Removal > Page 10469 2. Carefully pry the plastic nut cap (1) off of the pivot end of the wiper arm. 3. Remove the nut (2) that secures the wiper arm to the rear wiper motor output shaft (4). CAUTION: The use of a battery terminal puller when removing the rear wiper arm is NOT recommended as this may damage the front wiper arm. 4. Use a slight rocking action to disengage the rear wiper arm pivot end from the output shaft and remove the wiper arm. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Removal > Page 10470 Wiper Arm: Service and Repair Installation Front FRONT NOTE: Be certain that the wiper motor is in the park position before attempting to install the front wiper arms. Turn the ignition switch to the ON position and move the right (wiper) multi-function switch control knob to its OFF position. If the wiper pivots move, wait until they stop moving, then turn the ignition switch back to the OFF position. The front wiper motor is now in its park position. 1. The front wiper arms (2) must be indexed to the pivot shafts (5) with the front wiper motor in the park position to be properly installed. Position the wiper arm pivot end onto the wiper pivot shaft so that the wiper blade (1) is aligned with the wiper alignment lines (6), which are horizontal marks concealed in the upper margin of the lower windshield blackout area. 2. Once the wiper blade is aligned, lift the wiper arm away from the windshield slightly to relieve the spring tension on the pivot end and push the pivot end of the wiper arm down firmly and evenly over the pivot shaft. 3. Install and tighten the nut (3) that secures the wiper arm to the pivot shaft. Tighten the nut to 26 Nm (19 ft. lbs.). 4. Wet the windshield glass, then operate the front wipers. Turn the wiper switch to the OFF position, then check for the correct wiper arm position and readjust as required. 5. Reinstall the plastic nut cap (4) onto the wiper arm pivot nut. Rear REAR Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Removal > Page 10471 NOTE: Be certain that the rear wiper motor is in the park position before attempting to install the rear wiper arm. Turn the ignition switch to the ON position and move the rear wiper switch to its OFF position. If the wiper motor output shaft moves, wait until it stops moving, then turn the ignition switch back to the OFF position. The wiper motor is now in its park position. 1. The rear wiper arm (3) must be indexed to the motor output shaft (4) with the rear wiper motor in the park position to be properly installed. Position the wiper arm pivot end onto the output shaft so that the wiper blade (5) is aligned with the lowest horizontal line of the rear window defogger grid. 2. With the rear wiper arm properly indexed, push the tapered mounting hole on the pivot end of the wiper arm down over the output shaft. 3. Install and tighten the nut (2) that secures the rear wiper arm to the rear wiper motor output shaft. Tighten the nut to 9 Nm (7 ft. lbs.). 4. Wet the liftgate glass and operate the rear wiper. Turn the rear wiper switch to the OFF position, then check for correct wiper arm position and readjust as required. 5. Reinstall the plastic nut cap over the nut on the pivot end of the rear wiper arm. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Removal Wiper Blade: Service and Repair Removal REMOVAL CAUTION: Do not allow the wiper arm to spring back against the glass without the wiper blade in place or the glass may be damaged. NOTE: The notched end of the wiper element flexor should always be oriented towards the end of the wiper blade that is nearest to the wiper pivot. 1. Lift the wiper arm (2) to raise the wiper blade and element (6) off of the glass, until the wiper arm hinge is in its over-center position. 2. To remove the blade from the arm, depress the latch release tab (4) on the pivot block (3) under the tip of the arm and slide the blade away from the tip towards the pivot end of the arm far enough to disengage the pivot block from the hook formation (5) on the end of the arm. 3. Extract the hook formation on the tip of the wiper arm through the opening in the wiper blade superstructure (1) just ahead of the pivot block. 4. Gently lower the tip of the wiper arm onto the glass. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Removal > Page 10476 Wiper Blade: Service and Repair Installation INSTALLATION CAUTION: Do not allow the wiper arm to spring back against the glass without the wiper blade in place or the glass may be damaged. NOTE: The notched end of the wiper element flexor should always be oriented towards the end of the wiper blade that is nearest to the wiper pivot. 1. Lift the wiper arm (2) off of the windshield glass, until the wiper arm hinge is in its over-center position. 2. Position the wiper blade near the hook formation (5) on the tip of the arm with the notched end of the wiper element flexor oriented towards the end of the wiper arm that is nearest to the wiper pivot. 3. Insert the hook formation on the tip of the arm through the opening in the blade superstructure (1) ahead of the pivot block (3) far enough to engage the pivot block into the hook. 4. Slide the pivot block up into the hook formation on the tip of the wiper arm until the latch release tab (4) snaps into its locked position. Latch engagement will be accompanied by an audible click. 5. Gently lower the wiper blade and element (6) onto the glass. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Motor-Wiper-Front Wiper Motor: Locations Motor-Wiper-Front Component ID: 173 Component : MOTOR-WIPER-FRONT Connector: Name : MOTOR-WIPER-FRONT Color : LT. GRAY # of pins : 5 Pin Description Circuit 1 FRONT WIPER LOW SPEED CONTROL OUTPUT W3 16BR/WT Pin Description Circuit 1 FRONT WIPER PARK SWITCH SENSE W7 20BR/DB 2-3 FRONT WIPER PARK SWITCH SENSE W7 20BR/DB 3 FRONT WIPER HIGH SPEED CONTROL OUTPUT W4 16BR/LB 4 FRONT WIPER HIGH SPEED CONTROL OUTPUT W4 16BR/LB 4 GROUND Z971 16BK 5 GROUND Z971 16BK 5 FRONT WIPER LOW SPEED CONTROL OUTPUT W3 16BR/WT Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Motor-Wiper-Front > Page 10481 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Motor-Wiper-Front > Page 10482 Wiper Motor: Locations Motor-Wiper-Rear Component ID: 174 Component : MOTOR-WIPER-REAR Connector: Name : MOTOR-WIPER-REAR Color : GREEN # of pins : 4 Pin Description Circuit 1-2 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F996 18PK/YL 3 GROUND Z960 16BK/LB 4 REAR WIPER MOTOR CONTROL W13 20BR/LG Component Location - 67 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Motor-Wiper-Front > Page 10483 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions Wiper Motor: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: Provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10486 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10487 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10488 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10489 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10490 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10491 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10492 5. Release the Secondary Terminal Lock, if required (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10493 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10494 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10495 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10496 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10497 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10498 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10499 Wiper Motor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10500 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10501 STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10502 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10503 Wiper Motor: Connector Views Motor-Wiper-Front Component ID: 173 Component : MOTOR-WIPER-FRONT Connector: Name : MOTOR-WIPER-FRONT Color : LT. GRAY # of pins : 5 Pin Description Circuit 1 FRONT WIPER LOW SPEED CONTROL OUTPUT W3 16BR/WT Pin Description Circuit 1 FRONT WIPER PARK SWITCH SENSE W7 20BR/DB 2-3 FRONT WIPER PARK SWITCH SENSE W7 20BR/DB 3 FRONT WIPER HIGH SPEED CONTROL OUTPUT W4 16BR/LB 4 FRONT WIPER HIGH SPEED CONTROL OUTPUT W4 16BR/LB 4 GROUND Z971 16BK 5 GROUND Z971 16BK 5 FRONT WIPER LOW SPEED CONTROL OUTPUT W3 16BR/WT Component Location - 8 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10504 Motor-Wiper-Rear Component ID: 174 Component : MOTOR-WIPER-REAR Connector: Name : MOTOR-WIPER-REAR Color : GREEN # of pins : 4 Pin Description Circuit Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10505 1-2 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F996 18PK/YL 3 GROUND Z960 16BK/LB 4 REAR WIPER MOTOR CONTROL W13 20BR/LG Component Location - 67 Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Description and Operation > Module-Front Wiper Wiper Motor: Description and Operation Module-Front Wiper Description DESCRIPTION The front wiper module is secured to stamped brackets within the cowl plenum panel beneath the cowl plenum cover/grille panel. The ends of the wiper pivot shafts protrude through dedicated openings in the cowl plenum cover/grille panel to drive the wiper arms and blades and are the only visible components of the front wiper module. The front wiper module consists of the following major components: - Bracket - The front wiper module bracket (4) consists of a long tubular steel main member that has a stamped pivot bracket formation near each end where the two wiper pivots are secured. The front wiper module bracket is secured within the cowl plenum by two screws through two rubber insulators (6). Crank Arm - The front wiper motor crank arm (5) is a stamped steel unit with a slotted hole on the driven end that is secured to the wiper motor output shaft with a nut, and a ball stud secured to the drive end. - Linkage - Two stamped steel drive links (7) connect the wiper motor crank arm to the two wiper pivot lever arms. The passenger side link has a plastic socket-type bushing on each end, while the driver side link has a socket-type bushing on the pivot end and a sleeve-type bushing on the crank arm end. The bushing on the pivot end of each link is snap-fit over a ball stud on the pivot lever arm. The sleeve-type bushing on the driver side link is snap fit over the inner ball formation of a double ball stud on the crank arm, then the socket-type bushing of the passenger side drive link is snapped over the outer ball formation. - Motor - The front wiper motor (9) is secured by a bracket (3) integral to the motor transmission housing with two screws and nuts near the center of the wiper module bracket. A knob-like rubber insulator (8) on a stud integral to the motor transmission housing is engaged in a slot in a stamped bracket on the forward wall of the cowl plenum. The two-speed permanent magnet wiper motor features an integral transmission, an internal park switch, and an internal automatic resetting circuit breaker. - Pivots - The two front wiper pivots (1) are secured to the ends of the wiper module bracket. The lever arms that extend from the bottom of the pivot shafts each have ballstuds that engage the bushings of the drive links. A molded plastic shield (2) is fit over the top of each pivot housing. The upper end of each pivot shaft where the wiper arms will be fastened each is tapered and serrated with a threaded stud formation at the tip. The front wiper motor and crank arm unit is available for separate service replacement. Any other component of the front wiper module cannot be adjusted or repaired. If any component of the module other than the motor is ineffective or damaged, the entire front wiper module unit must be replaced. Operation OPERATION The front wiper module operation is controlled by the battery current inputs received by the wiper motor through the Totally Integrated Power Module (TIPM). The wiper motor speed is controlled by current flow to either the low speed or the high speed set of brushes. The park switch is a single pole, Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Description and Operation > Module-Front Wiper > Page 10508 single throw, momentary switch within the wiper motor that is mechanically actuated by the wiper motor transmission components. The park switch alternately closes the wiper park switch sense circuit to ground or to battery current, depending upon the position of the wipers on the glass. This feature allows the motor to complete its current wipe cycle after the wiper system has been turned OFF, and to park the wiper blades in the lowest portion of the wipe pattern. The automatic resetting circuit breaker protects the motor from overloads. The wiper motor crank arm, the two wiper linkage members and the two wiper pivots mechanically convert the rotary output of the wiper motor to the back and forth wiping motion of the wiper arms and blades on the glass. The hard wired inputs and outputs of the front wiper motor may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the front wiper motor or the electronic controls or communication between other modules and devices that provide some features of the front wiper and washer system. The most reliable, efficient, and accurate means to diagnose the front wiper motor or the electronic controls and communication related to front wiper motor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Description and Operation > Module-Front Wiper > Page 10509 Wiper Motor: Description and Operation Motor-Rear Wiper Description DESCRIPTION The rear wiper motor (4) is concealed within the liftgate, below the liftgate glass and behind the liftgate inner trim panel. The end of the motor output shaft (2) that extends through the lower edge of the liftgate glass to drive the rear wiper arm and blade is the only visible component of the rear wiper motor. A rubber grommet is engaged within the output shaft hole of the liftgate glass and seals the output shaft where it passes through the glass. An integral connector receptacle (3) connects the rear wiper motor to the vehicle electrical system through a dedicated take out and connector of the liftgate wire harness. The rear wiper motor consists of the following major components: - Bracket (5) - The rear wiper motor bracket consists of a stamped metal mounting plate for the wiper motor that is secured to the wiper motor housing, and through three screws with rubber isolators (1) to the liftgate inner panel. - Motor - The single-speed permanent magnet rear wiper motor is secured to the rear wiper motor bracket. The wiper motor includes an integral transmission, motor output shaft, automatic resetting circuit breaker and the rear wiper motor park switch. The rear wiper motor cannot be adjusted or repaired. If any component of the motor is ineffective or damaged, the entire rear wiper motor unit must be replaced. The motor output shaft rubber grommet is available for individual service replacement. Operation OPERATION The rear wiper motor operation is controlled by the Totally Integrated Power Module (TIPM), which uses intelligent, high current, self-protected high side switches to control rear wiper system operation for energizing or de-energizing the rear wiper motor. The TIPM uses internal programming and electronic messages received over the Controller Area Network (CAN) data bus from the Electromechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) to provide the appropriate rear wiper and washer system operating modes. The EMIC uses electronic messages received from the Steering Control Module (SCM) over a Local Interconnect Network (LIN) data bus to determine when to send electronic rear wiper system requests to the TIPM. The rear wiper motor park switch is a single pole, single throw, momentary switch within the wiper motor that is mechanically actuated by the wiper motor transmission components. The park switch alternately closes and opens a path to ground for the rear wiper motor electronic control logic circuitry of the TIPM, depending upon the position of the rear wiper blade on the liftgate glass. This input allows the electronic logic circuits of the TIPM to control all of the electronic features of rear wiper motor operation and to keep the motor energized long enough to complete its current wipe cycle and park the wiper blade after the wiper system or the ignition switch has been turned OFF. The rear wiper motor is grounded at all times through a take out with an eyelet terminal connector in the body wire harness that is secured to a ground location in the passenger compartment. The automatic resetting circuit breaker protects the motor from overloads. The rear wiper motor transmission converts the rotary output of the wiper motor to the back and forth wiping motion of the rear wiper arm and blade on the liftgate glass. The hard wired inputs and outputs of the rear wiper motor may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the rear wiper motor or the electronic controls or communication between other modules and devices that provide some features of the rear wiper and washer system. The most reliable, efficient, and accurate means to diagnose the rear wiper motor or the electronic controls and communication related to rear wiper motor Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Description and Operation > Module-Front Wiper > Page 10510 operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Module-Front Wiper Wiper Motor: Service and Repair Module-Front Wiper Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove both front wiper arms from the wiper pivots. 3. Remove the cowl plenum cover/grille panel from over the front wiper module. 4. Disengage the routing clip (2) from the stud in the cowl plenum and disconnect the wire harness (1) connector from the connector receptacle for the front wiper motor (3). 5. Remove the two screws (2) that secure the ends of the front wiper module bracket (3) to the stamped brackets (1) within the cowl plenum. 6. Pull the front wiper module inboard far enough to disengage the knob-like rubber isolator from the slotted bracket (4) on the forward wall of the cowl plenum. 7. Remove the front wiper module from the cowl plenum as a unit. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Module-Front Wiper > Page 10513 Installation INSTALLATION 1. Position the front wiper module (3) into the cowl plenum as a unit. 2. Position the knob-like rubber isolator to the slotted bracket (4) on the forward wall of the cowl plenum and pull the module outboard far enough to seat the isolator in the bracket. 3. Loosely install the two screws (2) that secure the ends of the front wiper module bracket to the stamped brackets (1) within the cowl plenum. 4. Tighten the two screws, driver side followed by passenger side. 5. Reconnect the wire harness (1) connector to the connector receptacle for the front wiper motor (3) and engage the routing clip onto the stud in the cowl plenum. 6. Reinstall the cowl plenum cover/grille panel over the front wiper module. NOTE: Be certain to turn the ignition switch to the ON position, then turn the front wiper switch ON and OFF again to cycle the wiper motor and linkage to their natural park position before reinstalling the front wiper arms onto the wiper pivots. 7. Reinstall both front wiper arms onto the wiper pivots. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Module-Front Wiper > Page 10514 8. Reconnect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Module-Front Wiper > Page 10515 Wiper Motor: Service and Repair Motor-Front Wiper Removal REMOVAL CAUTION: Do not apply pressure to, or pry on, the plastic drive link bushings. When removing the drive link from, or installing the drive link to the ball stud on the wiper motor crank arm, apply pressure to, or pry on, only the metal portions of the drive link around the bushing. If the bushing is damaged, the entire front wiper module MUST be replaced. CAUTION: Do not remove the crank arm nut from the wiper motor output shaft. The crank arm is indexed to the output shaft with the motor in the park position during the manufacturing process, but there are no provisions made for correctly indexing this connection in the field. If the crank arm to output shaft indexing is incorrect, the entire front wiper module MUST be replaced. 1. Disconnect and isolate the battery negative cable. 2. Remove the front wiper module (1) from the vehicle. 3. Disengage the socket bushing (3) of the passenger side wiper drive link from the ball stud on the wiper motor crank arm (4) using two large screwdrivers, one on each side of the ball stud. Pry firmly and evenly between the crank arm and the metal portion of the drive link until the socket unsnaps from the ball. 4. Remove the sleeve bushing (2) of the driver side wiper drive link from the ball stud on the wiper motor crank arm. 5. Remove the two screws (2) that secure the motor bracket (4) to the module bracket (1). 6. Remove the wiper motor and crank arm unit (5) from the underside of the module bracket. Installation Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Module-Front Wiper > Page 10516 INSTALLATION CAUTION: Do not apply pressure to, or pry on, the plastic drive link bushings. When removing the drive link from, or installing the drive link to the ball stud on the wiper motor crank arm, apply pressure to, or pry on, only the metal portions of the drive link around the bushing. If the bushing is damaged, the entire front wiper module MUST be replaced. CAUTION: Do not remove the crank arm nut from the wiper motor output shaft. The crank arm is indexed to the output shaft with the motor in the park position during the manufacturing process, but there are no provisions made for correctly indexing this connection in the field. If the crank arm to output shaft indexing is incorrect, the entire front wiper module MUST be replaced. 1. Position the front wiper motor and crank arm unit (5) to the underside of the front wiper module bracket (1). 2. Install and tighten the two screws (2) into the two nuts (3) that secure the motor bracket (4) to the module bracket. 3. Position the sleeve bushing (2) of the driver side wiper drive link onto the ball stud on the end of the motor crank arm (4). 4. Position the socket bushing (3) of the passenger side wiper drive link over the ball stud on the crank arm. 5. Place a short 19 millimeter or 3/4 inch socket over the domed cap side of the socket bushing as an installation tool. Use large channel-lock pliers to firmly and evenly apply enough pressure to the underside of the crank arm and the top of the socket installation tool to snap the bushing onto the ball stud. Do not apply pressure directly to the plastic bushings. NOTE: Be certain to turn the ignition switch to the ON position, then turn the front wiper switch ON and OFF again to cycle the wiper motor and linkage to their natural park position before reinstalling the front wiper arms onto the wiper pivots. 6. Reinstall the front wiper module (1) into the vehicle. 7. Reconnect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Module-Front Wiper > Page 10517 Wiper Motor: Service and Repair Motor-Rear Wiper Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the rear wiper arm from the rear wiper motor output shaft. 3. Remove the trim from the liftgate inner panel. 4. Disconnect the liftgate wire harness connector (2) from the rear wiper motor (4). 5. Remove the three screws (3) that secure the motor mounting bracket to the U-nuts (5) on the liftgate inner panel. 6. Pull the wiper motor forward far enough to disengage the output shaft from the rubber grommet (1) in the liftgate glass. 7. Remove the motor from the liftgate. 8. Remove the rubber grommet from the output shaft clearance hole in the liftgate glass and discard. Installation INSTALLATION 1. Install a new rubber grommet (1) into the rear wiper motor output shaft clearance hole located in the liftgate glass. Always use a new rubber grommet in the glass. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Module-Front Wiper > Page 10518 2. Check to be certain that the three U-nuts (2) are properly installed and in good condition in the liftgate inner panel (3). CAUTION: A new replacement rear wiper motor is shipped with a rubber lubricant applied to the motor output shaft where it contacts the rubber grommet in the liftgate glass. If a rear wiper motor is removed then reinstalled, an appropriate rubber lubricant (Mopar(R) Nye Synthetic Lubricant also known as Fluorocarbon Gel 880 Synthetic Lubricant) must be applied to the motor output shaft in the area just below the taper where the shaft will contact the grommet before the motor is reinstalled. Failure to comply with this caution can result in premature grommet failure, excessive motor loads and water leaks. 3. Insert the rear wiper motor (4) output shaft through the rubber grommet (1) in the liftgate glass. 4. Position the rear wiper motor and mounting bracket to the U-nuts (5) in the liftgate inner panel as a unit 5. Install and tighten the three screws (3) that secure the motor mounting bracket to the liftgate. 6. Reconnect the liftgate wire harness connector (2) to the wiper motor connector receptacle. 7. Reinstall the trim onto the liftgate inner panel. 8. Reinstall the rear wiper arm onto the output shaft. 9. Reconnect the battery negative cable. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Description Wiper Switch: Description and Operation Description DESCRIPTION The right (wiper) multi-function switch is located on the right side of the steering column, just below the steering wheel. This switch is the primary control for the front and rear wiper and washer systems. The only visible components of the switch are the control stalk (1), control knob (2) and control sleeve (3) that extend through the steering column shrouds on the right side of the column. The remainder of the switch including its mounting provisions and electrical connection are concealed beneath the shrouds. The switch housing and controls (6) are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. A single screw (7) through a mounting tab integral to the back of the switch housing, and a slide tab integral to the bottom of the switch housing secure the switch to the mounting bracket integral to the clockspring (3). A single connector receptacle containing seven terminal pins is integral to the inboard end of the switch housing and is connected by a jumper wire harness (5) directly to the Steering Control Module (SCM), which is internal to the housing (2) of the left multi-function switch (1). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Description > Page 10523 The right (wiper) multi-function switch provides the vehicle operator with a control interface for the following wiper and washer system functions: - Continuous Front Wipers - The right multi-function switch control knob provides detent switching for two continuous front wipe modes, low speed or high speed. Intermittent Front Wipers - The right multi-function switch control knob provides detent switching for the intermittent front wipe mode with five minor detent delay interval positions. - Front Wiper Mist Mode - The right multi-function switch control stalk includes momentary switching of the front wiper motor low speed circuit to provide a mist mode features (sometimes referred to as pulse wipe), which allows the vehicle operator to momentarily operate the front wipers for one or more complete cycles. - Front Washer Mode - The right multi-function switch control stalk provides momentary switching for control of the front washer system operation. - Intermittent Rear Wipe Mode - The right multi-function switch control sleeve provides detent switching for a single fixed interval intermittent rear wiper mode. - Rear Washer Mode - The right multi-function switch control sleeve provides two momentary switch positions for control of rear washer system operation. The right multi-function switch cannot be adjusted or repaired. If any function of the switch is ineffective, or if the switch is damaged, the entire switch unit must be replaced. The clockspring (with the multi-function switch mounting bracket), the left multi-function switch (with the SCM), the right multi-function switch and the jumper wire harness are each available for separate service replacement. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Description > Page 10524 Wiper Switch: Description and Operation Operation OPERATION The right (wiper) multi-function switch uses a combination of resistor multiplexing and conventional switching to control the many functions and features it provides. The switch receives a clean ground from the Steering Control Module (SCM), then provides resistor multiplexed and conventional analog return outputs to the SCM to indicate the selected switch positions. The SCM then sends electronic switch status messages over a Local Interface Network (LIN) data bus to the Electromechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN), and the EMIC relays electronic wiper and washer switch request messages over the Controller Area Network (CAN) data bus to other electronic modules in the vehicle. If the SCM detects no inputs from the right multi-function switch, it transmits an electronic Signal Not Available (SNA) status message over the LIN data bus. The SNA status signals the EMIC to request other electronic modules to implement a failsafe mode of operation for the front and rear wiper systems. The failsafe mode will maintain the last selected front and rear wiper system operation for the remainder of the current ignition cycle, after which both wiper systems will default to OFF. The right multi-function switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, the most reliable, efficient and accurate means to diagnose this component requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Following are descriptions of how the right multi-function switch is operated to control the many front and rear wiper and washer system functions and features it provides: - Front Wiper Control - The control knob on the end of the right multi-function switch control stalk is rotated to one of the two continuous wiper detents, to one of five intermittent wiper detents, or to the OFF position to select the front wiper mode. The SCM reads the input from the right multi-function switch and sends electronic wiper switch status messages over the LIN data bus to the EMIC, which relays an electronic wiper switch request message over the CAN data bus to other electronic modules in the vehicle. - Front Wiper Mist Mode - The front wiper mist mode is requested when the right multi-function switch control stalk is depressed downward towards the floor to a momentary MIST position. The front wiper motor will continue to operate, one complete cycle at a time, for as long as the control stalk is held in this position. The SCM reads the resistor multiplexed input from the right multi-function switch and sends an electronic wiper switch status message over the LIN data bus to the EMIC, which relays an electronic wiper switch request message over the CAN data bus to other electronic modules in the vehicle. - Front Washer Control - The right multi-function switch control stalk is pulled rearward towards the steering wheel to a momentary WASH position to activate the washer pump/motor in the front washer mode. The washer pump/motor will continue to operate for as long as the control stalk is held in this position. The SCM reads the resistor multiplexed input from the right multi-function switch and sends an electronic washer switch status message over the LIN data bus to the EMIC, which relays an electronic washer switch request message over the CAN data bus to other electronic modules in the vehicle. - Rear Wiper Control - The rear wiper mode is selected when the right multi-function switch control sleeve is rotated to the fixed interval intermittent rear wipe detent position, or the OFF detent position. The SCM reads the input from the right multi-function switch and sends an electronic wiper switch status message over the LIN data bus to the EMIC, which relays an electronic wiper switch request message over the CAN data bus to other electronic modules in the vehicle. - Rear Washer Control - The right multi-function switch control sleeve is rotated to one of two momentary WASH positions, either fully forward or fully rearward, to activate the washer pump/motor in the rear washer mode. The washer pump/motor will continue to operate in the rear washer mode until the control sleeve is released. The SCM reads the input from the right multi-function switch and sends an electronic washer switch status message over the LIN data bus to the EMIC, which relays an electronic washer switch request message over the CAN data bus to other electronic modules in the vehicle. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 10525 Wiper Switch: Testing and Inspection RIGHT MULTI-FUNCTION SWITCH WARNING: To avoid personal injury or death, on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, occupant classification system, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. The right multi-function switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the Steering Control Module (SCM) or the electronic controls or communication between other modules and devices that provide some features of the front and rear wiper and washer systems. The most reliable, efficient and accurate means to diagnose the SCM or the electronic controls and communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. 1. Remove the right multi-function switch from the integral mounting bracket on the right side of the clockspring. 2. Using an ohmmeter, test the resistance between the terminals of the switch as shown in the three Function Tests tables. For all functions except those of the control stalk the values should be either less than 100 ohms (switch CLOSED) or greater than 1 megohm (switch OPEN). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 10526 3. If the switch fails any of the tests, replace the ineffective right multi-function switch as required. If the switch tests okay, but the switch input to the Steering Control Module (SCM) remains incorrect, be certain to check for a short or open in the jumper harness between the right multi-function switch and the SCM. Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Removal Wiper Switch: Service and Repair Removal REMOVAL WARNING: To avoid personal injury or death, on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, occupant classification system, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove both the upper and lower shrouds from the steering column. 3. Remove the screw (2) that secures the right multi-function switch (1) to the mounting bracket integral to the right side of the clockspring (3) on the steering column. 4. Slide the switch away from the clockspring far enough to disengage the slide tab on the bottom of the switch housing from the channel formation in the mounting bracket. 5. Disconnect the jumper wire harness connector (1) from the connector receptacle on the inboard end of the right multi-function switch (2). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Removal > Page 10529 6. Remove the switch from the clockspring (3). Dodge Caliber Srt-4 Workshop Manual (L4-2.4L Turbo VIN F (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Removal > Page 10530 Wiper Switch: Service and Repair Installation INSTALLATION WARNING: To avoid personal injury or death, on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, occupant classification system, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the right multi-function switch (2) close enough to the mounting bracket (3) integral to the right side of the clockspring to reconnect the jumper wire harness connector (1) to the connector receptacle on the inboard side of the switch housing. 2. Align the slide tab on the bottom of the switch housing with the channel integral to the clockspring mounting bracket, then slide the switch into the bracket until it is firmly seated. 3. Install and tighten the screw (2) that secures the mounting tab on the back of the right multi-function switch (1) to the mounting bracket on the clockspring (3). 4. Reinstall the upper and lower shrouds onto the steering column.