Dodge Caliber 2007 Factory Service Manual
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GROUP TAB LOCATOR
Introduction
0 Lubrication & Maintenance
2 Suspension
3 Differential & Driveline
4 Vehicle Quick Reference
5 Brakes
6 Clutch
7 Cooling
8A Audio/Video
8B Chime/Buzzer
8E Electronic Control Modules
8F Engine Systems
8G Heated Systems
8H Horn
8I Ignition Control
8J Instrument Cluster
8L Lamps
8M Message Systems
8N Power Systems
8O Restraints
8P Speed Control
8Q Vehicle Theft Security
8R Wipers/Washers
8T Navigation/Telecommunication
8W Wiring
9 Engine
11 Exhaust System
13 Frame & Bumpers
14 Fuel System
19 Steering
21 Transmission and Transfer Case
22 Tires/Wheels
23 Body
24 Heating & Air Conditioning
25 Emissions Control
Component and System Index
DTC Index
Service Manual Comment Forms (Rear of Manual)
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PM INTRODUCTION 1
INTRODUCTION
TABLE OF CONTENTS
page page
BODY CODE PLATE VEHICLE IDENTIFICATION NUMBER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 DESCRIPTION - VEHICLE IDENTIFICATION
FASTENER IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 VEHICLE CERTIFICATION LABEL
FASTENER USAGE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DESCRIPTION E-MARK LABEL
FASTENER USAGE . . . . . . . . . . . . . . . . . . . . . . . . . . 6 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
THREADED HOLE REPAIR . . . . . . . . . . . . . . . . . . . 6 VECI LABEL
INTERNATIONAL SYMBOLS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 MANUFACTURER PLATE
METRIC SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TORQUE REFERENCES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2 INTRODUCTION PM
BODY CODE PLATE
DESCRIPTION
The Body Code Plate is located in the engine compartment on the plenum behind the right side strut tower. There
are seven lines of information on the body code plate. Lines 4, 5, 6, and 7 are not used to define service informa-
tion. Information reads from left to right, starting with line 3 in the center of the plate to line 1 at the bottom of the
plate.
BODY CODE PLATE LINE 2
DIGITS 1, 2, AND 3
Paint procedure
DIGIT 4
Open Space
DIGITS 5 THROUGH 7
Primary paint
(Refer to 23 - BODY/PAINT - SPECIFICATIONS) for
Body Color Codes.
DIGIT 8 AND 9
Open Space
DIGITS 10 THROUGH 12
Secondary Paint
DIGIT 13 AND 14
Open Space
DIGITS 15 THROUGH 18
Interior Trim Code
DIGIT 19
Open Space
DIGITS 20, 21, AND 22
Engine Code
• EJD = 1.6L Four Cylinder 16 Valves SOHC Gasoline
• ECC = 2.0L Four Cylinder 16 Valves DOHC Gasoline
• EDJ = 2.2L Four Cylinder Turbo Diesel Engine
• EDZ = 2.4L Four Cylinder 16 Valves DOHC Gasoline
• EDV = 2.4L Four Cylinder 16 Valves DOHC H.O. Turbo Gasoline
DIGIT 23
Open Space
PM INTRODUCTION 3
BODY CODE PLATE LINE 1
DIGITS 1, 2, AND 3
Transaxle Codes
• DGL = 41TE 4-Speed Electronic Automatic Transaxle
• DD5 = NV T350 5-Speed Manual Transaxle
• DDD = GETRAG 288 5-Speed Manual Transaxle
DIGIT 4
Open Space
DIGIT 5
Market Code
• C = Canada
• B = International
• M = Mexico
• U = United States
DIGIT 6
Open Space
DIGITS 7 THROUGH 23
Vehicle Identification Number
• (Refer to VEHICLE DATA/VEHICLE INFORMATION/VEHICLE IDENTIFICATION NUMBER - DESCRIPTION)
for proper breakdown of VIN code.
IF TWO BODY CODE PLATES ARE REQUIRED
The last code shown on either plate will be followed by END. When two plates are required, the last code space on
the first plate will indicate (CTD)
When a second plate is required, the first four spaces of each line will not be used due to overlap of the plates.
4 INTRODUCTION PM
FASTENER IDENTIFICATION
DESCRIPTION
The SAE bolt strength grades range from grade 2 to grade 8. The higher the grade number, the greater the bolt
strength. Identification is determined by the line marks on the top of each bolt head. The actual bolt strength grade
corresponds to the number of line marks plus 2. The most commonly used metric bolt strength classes are 8.9 and
10.9. The metric strength class identification number is imprinted on the head of the bolt. The higher the class
number, the greater the bolt strength. Some metric nuts are imprinted with a single-digit strength class on the nut
face. Refer to the Fastener Identification and Fastener Strength Charts.
Bolt Markings and Torques - Metric
Bolt Markings 8.8/8.9 10.9 12.9
Bolt Dia. N·m Ft. Lbs. N·m Ft. Lbs. N·m Ft. Lbs.
6 12 105* 14 120* 16 12
8 25 250* 32 23 38 28
10 54 40 60 45 74 55
12 95 70 108 80 135 100
14 155 115 175 130 216 160
16 243 180 324 210 324 240
* Inch Lbs.
Bolt Markings and Torques - U. S. Customary
Bolt Markings Grade 5 Grade 8
Bolt Dia. N·m Ft. Lbs N·m Ft. Lbs
1/4 - 20 10 95* 14 125*
1/4 - 28 10 95* 17 150*
5/16 - 18 22 200* 30 270*
5/16 - 24 26 240* 33 300*
3/8 - 16 40 30 55 40
3/8 - 24 47 35 60 45
7/16 - 14 68 50 88 65
7/16 - 20 74 55 95 70
1/2 - 13 101 75 135 100
1/2 -20 115 85 150 110
9/16 - 12 135 105 182 135
9/16 - 18 155 115 202 150
5/8 - 11 202 150 263 195
5/8 - 18 215 160 284 210
3/4 - 10 230 170 297 220
3/4 - 16 236 175 304 225
7/8 - 14 405 300 540 400
* Inch Lbs.
PM INTRODUCTION 5
6 INTRODUCTION PM
FASTENER USAGE
DESCRIPTION
FASTENER USAGE
WARNING: Use of an incorrect fastener may result in component damage or personal injury.
Fasteners and torque specifications references in this Service Manual are identified in metric and SAE format.
During any maintenance or repair procedures, it is important to salvage all fasteners (nuts, bolts, etc.) for reassem-
bly. If the fastener is not salvageable, a fastener of equivalent specification must be used.
THREADED HOLE REPAIR
Most stripped threaded holes can be repaired using a HelicoilT. Follow the vehicle or HelicoilT recommendations for
application and repair procedures.
PM INTRODUCTION 7
INTERNATIONAL SYMBOLS
DESCRIPTION
The graphic symbols illustrated in the following International Control and Display Symbols Chart are used to identify
various instrument controls. The symbols correspond to the controls and displays that are located on the instrument
panel.
8 INTRODUCTION PM
METRIC SYSTEM
DESCRIPTION
The metric system is based on quantities of one, ten, one hundred, one thousand and one million.
The following chart will assist in converting metric units to equivalent English and SAE units, or vise versa.
PM INTRODUCTION 9
CONVERSION FORMULAS AND EQUIVALENT VALUES
MULTIPLY BY TO GET MULTIPLY BY TO GET
in-lbs x = Newton Meters N·m x 8.851 = in-lbs
0.11298 (N·m)
ft-lbs x = Newton Meters N·m x = ft-lbs
1.3558 (N·m) 0.7376
Inches Hg (60° F) x 3.377 = Kilopascals (kPa) kPa x = Inches Hg
0.2961
psi x 6.895 = Kilopascals (kPa) kPa x 0.145 = psi
Inches x 25.4 = Millimeters (mm) mm x = Inches
0.03937
Feet x = Meters (M) M x 3.281 = Feet
0.3048
Yards x = Meters M x = Yards
0.9144 1.0936
mph x = Kilometers/Hr. Km/h x = mph
1.6093 (Km/h) 0.6214
Feet/Sec x = Meters/Sec (M/S) M/S x 3.281 = Feet/Sec
0.3048
mph x = Meters/Sec (M/S) M/S x 2.237 = mph
0.4470
Kilometers/Hr. (Km/h) x = Meters/Sec (M/S) M/S x 3.600 Kilometers/Hr. (Km/h)
0.27778
COMMON METRIC EQUIVALENTS
1 inch = 25 Millimeters 1 Cubic Inch = 16 Cubic Centimeters
1 Foot = 0.3 Meter 1 Cubic Foot = 0.03 Cubic Meter
1 Yard = 0.9 Meter 1 Cubic Yard = 0.8 Cubic Meter
1 Mile = 1.6 Kilometers
Refer to the Metric Conversion Chart to convert torque values listed in metric Newton- meters (N·m). Also, use the
chart to convert between millimeters (mm) and inches (in.).
10 INTRODUCTION PM
TORQUE REFERENCES
DESCRIPTION
Individual Torque Charts appear within many or the Groups. Refer to the Standard Torque Specifications Chart for
torque references not listed in the individual torque charts.
PM INTRODUCTION 11
VEHICLE IDENTIFICATION NUMBER
DESCRIPTION - VEHICLE IDENTIFICATION NUMBER
The Vehicle Identification Number (VIN) is located on the upper left corner of the instrument panel, near the left
A-Pillar. The VIN consists of 17 characters in a combination of letters and numbers that provide specific information
about the vehicle. Refer to VIN Code Decoding Chart.
To protect the consumer from theft and possible fraud the manufacturer is required to include a Check Digit at the
ninth position of the Vehicle Identification Number. The check digit is used by the manufacturer and government
agencies to verify the authenticity of the vehicle and official documentation. The formula to use the check digit is not
released to the general public.
VIN CODE DECODING
POSITION INTERPRETATION CODE = DESCRIPTION
1 Country of Origin 1 = Manufactured by DiamlerChrysler Corporation
2 Make B = Dodge
3 Vehicle Type 3 = Passenger Car
D = Restraint System With Out Air Bags Sales Code
(CGJ) (Mexico)
H = Restraint System Air Bags Front Next Generation
Multi Stage Sales Code ( CG1 ) With Side Air Bags Sales
4 Restraint System
Code ( CGS )
J = Restraint System Air Bags Front Next Generation
Multi Stage Sales Code ( CG1 ) Without Side Air Bags
Sales Code ( CGS )
B = Caliber (FWD) (LHD U.S., Canada, Mexico , BUX
5 Vehicle Line E = Caliber (AWD) (LHD) U.S., Canada, Mexico
3 = Caliber (FWD) (RHD) BUX
2 = L ( Low Line)
4 = H ( High Line )
6 = S ( Sport )
7 = X ( Special )
6 Series
C = 6 Speed Manual Heavy Duty, Sales Code ( DEF )
C = 6 Speed Manual, Sales Code ( DEK )
G = Continuously Variable, Sales Code ( DAV )
N = 5 Speed Manual, Sales Code ( DD7 )
12 INTRODUCTION PM
POSITION INTERPRETATION CODE = DESCRIPTION
7 Body Style 8 = PM 49 4dr Hatchback
VIN CODE DECODING
A = 2.0L I4 CYL 16V DOHC Diesel Sales Code ( ECD )
B = 2.0L I4 CYL 16V DOHC Dual VVT Gasoline Sales
Code ( ECN )
C = 1.8L I4 CYL 16V DOHC Dual VVT Gasoline Sales
8 Engine Code ( EBA )
F = 2.4L I4 CYL 16V DOHC Turbo Gasoline Sales Code
(ED4)
K = 2.4L I4 CYL 16V Dual VVT Gasoline Sales Code
(ED3)
9 Check Digit 0 Thru 9 or X.
10 Model Year 7 = Model Year 2007
11 Assembly Plant D = Belvedere Assembly
12 Though 17 Vehicle Build Sequence 6 digit number assigned by assembly plant.
PM INTRODUCTION 13
VEHICLE CERTIFICATION LABEL
DESCRIPTION
A vehicle certification label is attached to the rear shutface of the driver’s door. This label indicates date of manu-
facture (month and year), Gross Vehicle Weight Rating (GVWR), Gross Axle Weight Rating (GAWR) front, Gross
Axle Weight Rating (GAWR) rear and the Vehicle Identification Number (VIN). The Month, Day and Hour of man-
ufacture is also included.
All communications or inquiries regarding the vehicle should include the Month-Day-Hour and Vehicle Identification
Number.
14 INTRODUCTION PM
E-MARK LABEL
DESCRIPTION
An E-mark Label is located on the rear shut face of the driver’s door. The label contains the following information:
• Date of Manufacture
• Month-Day-Hour (MDH)
• Vehicle Identification Number (VIN)
• Country Codes
• Regulation Number
• Regulation Amendment Number
• Approval Number
PM INTRODUCTION 15
VECI LABEL
DESCRIPTION
All models have a Vehicle Emission Control Information (VECI) Label. Chrysler permanently attaches the label in
the engine compartment. It cannot be removed without defacing information and destroying the label.
The label contains the vehicle’s emission specifications and vacuum hose routings. All hoses must be connected
and routed according to the label.
16 INTRODUCTION PM
MANUFACTURER PLATE
DESCRIPTION
The Manufacturer Plate is located in the engine compartment on the passenger side rear corner of the hood. The
plate contains five lines of information:
1. Vehicle Identification Number (VIN)
2. Gross Vehicle Mass (GVM)
3. Gross Train Mass (GTM)
4. Gross Front Axle Rating (GFAR)
5. Gross Rear Axle Rating (GRAR)
PM LUBRICATION & MAINTENANCE 0-1
LUBRICATION & MAINTENANCE
TABLE OF CONTENTS
page page
INTERNATIONAL SYMBOLS LUBRICATION POINTS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
FLUID TYPES MAINTENANCE SCHEDULES
DESCRIPTION DESCRIPTION
ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . 11
ENGINE COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . 4 MAINTENANCE SCHEDULES - GASOLINE
TRANSMISSION FLUID . . . . . . . . . . . . . . . . . . . . . . . 5 ENGINES - EXPORT . . . . . . . . . . . . . . . . . . . . . . . 16
FUEL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . 5 HOISTING
BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 STANDARD PROCEDURE - HOISTING . . . . . . . . . 22
POWER STEERING FLUID . . . . . . . . . . . . . . . . . . . . 7 JUMP STARTING
FLUID CAPACITIES STANDARD PROCEDURE - JUMP STARTING . . . 23
SPECIFICATIONS - FLUID CAPACITIES . . . . . . . . . . 8 TOWING
FLUID FILL/CHECK LOCATIONS STANDARD PROCEDURE - TOWING . . . . . . . . . . . 25
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
0-2 LUBRICATION & MAINTENANCE PM
INTERNATIONAL SYMBOLS
DESCRIPTION
DaimlerChrysler Corporation uses international symbols to identify engine compartment lubricant and fluid inspection
and fill locations.
Dodge Caliber 2007 Factory Service Manual
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PM LUBRICATION & MAINTENANCE 0-3
FLUID TYPES
DESCRIPTION
ENGINE OIL
WARNING: New or used engine oil can be irritating to the skin. Avoid prolonged or repeated skin contact
with engine oil. Contaminants in used engine oil, caused by internal combustion, can be hazardous to your
health. Thoroughly wash exposed skin with soap and water. Do not wash skin with gasoline, diesel fuel,
thinner, or solvents, health problems can result. Do not pollute, dispose of used engine oil properly. Contact
your dealer or government agency for location of collection center in your area.
When service is required, DaimlerChrysler Corporation recommends that only MoparT brand parts, lubricants and
chemicals be used. MoparT provides the best engineered products for servicing DaimlerChrysler Corporation vehi-
cles.
Only lubricants bearing designations defined by the following organization should be used.
• Society of Automotive Engineers (SAE)
• American Petroleum Institute (API)
• National Lubricating Grease Institute (NLGI)
• Association des Constructeurs Européens d’ Automobiles (European Automobile Manufacturers Association)
(ACEA)
API CERTIFICATION AND LICENSE SYMBOL
Use an engine oil that is API Certified and Licensed to
display the certification mark. MOPART provides
engine oils that meet or exceed, Material Standard
MS-6395 requirement.
SAE VISCOSITY
SAE 5W-20 and SAE 5W-30 engine oils are recom-
mended for all operating temperatures. These
engine oils are designed to improve low tempera-
ture starting and vehicle fuel economy. Refer to
the engine oil filler cap for the preferred engine oil
viscosity grade for each vehicle. SAE viscosity
grades are used to specify the correct viscosity oil for
an engine. Use only Multi-Viscosity oils such as SAE
5W-20 or 5W-30. These are specified with a dual SAE
viscosity grade which indicates the cold (5W) to hot
(20, 30) temperature performance range of the oil.
ACEA CATEGORIES
For countries that use the ACEA European Oil Categories for service fill oils, use engine oils that meet the require-
ments of ACEA A1/B1, A2/B2, or A3/B3.
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