Dodge Caliber 2007–2009 Service Manual

This Dodge Caliber PM service manual brings together DaimlerChrysler factory repair information covering chassis, powertrain, electrical, and body systems.

Service Text, Bookmarks, and Wiring Detail

Search and navigation: Service text is searchable, but many wiring sheets have no searchable text. Embedded PDF bookmarks cover system groups and procedures, although some opening bookmarks are inactive or misdirected. Small wiring labels require zooming for comfortable reading.

The ZIP contains one printable, 5,817-page PDF, including a cover page, foreword, group locator, two comment/address pages, and 41 blank pages.

Powertrain, Chassis, and Electrical Repair

These selected coverage highlights show part of the manual's scope. Other topics include starting and charging-system tests and evaporative-emissions service.

• Gasoline engine repair: Step-by-step instructions for engine removal, cylinder-head service, crankshaft and piston work, bearing selection, valve-lash measurement, and timing-chain installation for the 1.8L, 2.0L, and 2.4L World engines.

• T355 manual transaxle and CVT: Synchronizer service, differential bearing preload and shim selection, CVT disassembly and assembly, forward-clutch inspection, valve-body service, and hydraulic test ports.

• AWD driveline service: Front and rear halfshafts, CV boots, propeller-shaft replacement, rear driveline module overhaul, power transfer unit service, and electrical diagnosis of the electronically controlled AWD clutch.

• Front and rear suspension: Wheel-bearing and hub diagnosis, MacPherson strut disassembly, control-arm and link replacement, rear shock assembly service, curb-height measurement, and wheel alignment. Rear hub procedures distinguish FWD from AWD.

• Brakes and steering: Disc and rear drum brake service, base-system and ABS bleeding, hydraulic control unit replacement, power-steering flow and pressure testing, and steering-system bleeding.

• Electrical fault tracing: DTC-specific diagnostic tests for engine controls, ABS/ESP, restraints, vehicle security, and body electronics, supported by wiring diagrams, connector pin-outs, and connector, ground, and splice locations.

• HVAC and body repair: A/C performance and leak testing, refrigerant recovery and charging, heater-core and evaporator replacement, water-leak diagnosis, and body opening dimensions.

The foreword identifies professional automotive technicians performing daily repair work as its intended readers.

Model and Powertrain Coverage

The service information is organized around the 2007 Dodge Caliber PM platform, with FWD and AWD procedures and selected left-hand-drive, right-hand-drive, and export distinctions. Vehicle identification references help establish the configuration before choosing a procedure.

Diesel diagnosis: Mechanical engine chapters cover the naturally aspirated gasoline engines. The 2.0L diesel electrical diagnostic section addresses no-start and low-power complaints, turbocharger boost control, glow-plug circuits, injector circuits, EGR operation, and sensor calibration checks. It does not provide a complete diesel engine overhaul chapter.

Clutch and transaxle coverage: Clutch diagnosis distinguishes T355-equipped and BG6-equipped applications, including differences between modular-clutch replacement and separate clutch-disc service. Internal manual-transaxle repair coverage is specifically organized under the T355 chapter; the BG6 references do not constitute a separate gearbox overhaul section.

Diagnostic Tests and Service Illustrations

Gasoline engine diagnosis includes compression and cylinder-leakage testing, oil-pressure checks, and oil-leak inspection. Separate GPEC and diesel diagnostic sections connect symptoms and fault codes to circuit tests and verification procedures.

Module replacement: PCM/ECM/SKREEM programming information, pinion-factor setting, and TCM initialization and relearn procedures address setup following module or transaxle replacement. These sections assume access to appropriate diagnostic equipment.

Circuit and component references: The wiring group includes Bus Communications, Fuel/Ignition System, and Transmission Control System diagrams. Connector Pin-Outs supports terminal identification, while Connector/Ground/Splice Location provides vehicle-location illustrations. Base Brake System Diagnosis Charts adds symptom-based troubleshooting for hydraulic and mechanical brake complaints.

Body coverage also supplies gap-and-flush specifications, sealer and structural-adhesive locations, and weld-location illustrations for assessing the extent of body repair work.

Cooling, Fuel Delivery, and Maintenance

Cooling-system diagnosis includes pressure testing and overheating charts, with radiator, thermostat, and water-pump service. Fuel-delivery procedures distinguish FWD and AWD fuel-pump-module removal.

Lubrication and maintenance sections provide fluid specifications, capacities, fill/check locations, maintenance schedules, and hoisting and towing information. Component-specific torque tables use metric and customary units, including inch-pounds where applicable. Engine clearances, alignment specifications, transmission adjustment data, and electrical test values accompany the relevant systems.

Special Tools and Component Handling

Special-tool references include Knuckle Support Fixture 9712, Strut Nut Wrench 9362, and engine Locking Wedge 9701. These references help shops identify the equipment called for before starting a repair.

The suspension cautions explain how loading or rolling the vehicle with a loosened hub nut can damage the wheel bearing. Engine procedures also flag impact-wrench use on camshaft sprocket bolts as a risk to the locating dowel and camshaft phaser.

Working with heavy suspension components and compressed springs carries physical risks. Follow the manual's safety precautions and secure the vehicle properly before service.

Selected Alignment and CVT Installation Specifications

Alignment reference: At curb height, the preferred total toe is +0.10° at the front and +0.20° at the rear. The alignment table also lists acceptable ranges and explains how total toe relates to individual wheel settings.

CVT installation: The transmission specification table lists a minimum torque-converter installed depth of 13 mm, alongside oil-pump-drive-sprocket clearance and component-specific torque data.