Dodge Caliber. Manual - part 1316

Throughout this group, references to the DaimlerChrysler Corporation vehicle family identification code are used
when describing a procedure that is unique to that vehicle. Refer to Introduction Group of this manual for detailed
information on vehicle identification. If a procedure is common to all vehicles covered in this manual, no reference
will be made to a vehicle family code.

WARNING

SAFETY PRECAUTIONS AND WARNINGS

WARNING: USE AN OSHA APPROVED BREATHING FILTER WHEN SPRAYING PAINT OR SOLVENTS IN A
CONFINED AREA. PERSONAL INJURY CAN RESULT.
AVOID PROLONGED SKIN CONTACT WITH PETROLEUM OR ALCOHOL – BASED CLEANING SOLVENTS.
PERSONAL INJURY CAN RESULT.
DO NOT STAND UNDER A HOISTED VEHICLE THAT IS NOT PROPERLY SUPPORTED ON SAFETY STANDS.
PERSONAL INJURY CAN RESULT.

CAUTION: When holes must be drilled or punched in an inner body panel, verify depth of space to the outer
body panel, electrical wiring, or other components. Damage to vehicle can result.
Do not weld exterior panels unless combustible material on the interior of vehicle is removed from the
repair area. Fire or hazardous conditions, can result.
Always have a fire extinguisher ready for use when welding.
Disconnect the negative (-) cable clamp from the battery when servicing electrical components that are live
when the ignition is OFF. Damage to electrical system can result.
Do not use abrasive chemicals or compounds on painted surfaces. Damage to finish can result.
Do not use harsh alkaline based cleaning solvents on painted or upholstered surfaces. Damage to finish or
color can result.
Do not hammer or pound on plastic trim panel when servicing interior trim. Plastic panels can break.

DIAGNOSIS AND TESTING

WATER LEAKS

Water leaks can be caused by poor sealing, improper body component alignment, body seam porosity, missing
plugs, or blocked drain holes. Centrifugal and gravitational force can cause water to drip from a location away from
the actual leak point, making leak detection difficult. All body sealing points should be water tight in normal wet-
driving conditions. Water flowing downward from the front of the vehicle should not enter the passenger or luggage
compartment. Moving sealing surfaces will not always seal water tight under all conditions. At times, side glass or
door seals will allow water to enter the passenger compartment during high pressure washing or hard driving rain
(severe) conditions. Overcompensating on door or glass adjustments to stop a water leak that occurs under severe
conditions can cause premature seal wear and excessive closing or latching effort. After completing a repair, water
test vehicle to verify leak has stopped before returning vehicle to use.

VISUAL INSPECTION BEFORE WATER LEAK TESTS

Verify that floor and body plugs are in place, body drains are clear, and body components are properly aligned and
sealed. If component alignment or sealing is necessary, refer to the appropriate section of this group for proper
procedures.

WATER LEAK TESTS

WARNING: DO NOT USE ELECTRIC SHOP LIGHTS OR TOOLS IN WATER TEST AREA. PERSONAL INJURY
CAN RESULT.

When the conditions causing a water leak have been determined, simulate the conditions as closely as possible.

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If a leak occurs with the vehicle parked in a steady light rain, flood the leak area with an open-ended garden
hose.

•

If a leak occurs while driving at highway speeds in a steady rain, test the leak area with a reasonable velocity
stream or fan spray of water. Direct the spray in a direction comparable to actual conditions.

•

If a leak occurs when the vehicle is parked on an incline, hoist the end or side of the vehicle to simulate this
condition. This method can be used when the leak occurs when the vehicle accelerates, stops or turns. If the
leak occurs on acceleration, hoist the front of the vehicle. If the leak occurs when braking, hoist the back of the
vehicle. If the leak occurs on left turns, hoist the left side of the vehicle. If the leak occurs on right turns, hoist
the right side of the vehicle. For hoisting recommendations (Refer to LUBRICATION & MAINTENANCE/HOIST-
ING - STANDARD PROCEDURE).

WATER LEAK DETECTION

To detect a water leak point-of-entry, do a water test and watch for water tracks or droplets forming on the inside of
the vehicle. If necessary, remove interior trim covers or panels to gain visual access to the leak area. If the hose
cannot be positioned without being held, have someone help do the water test.

Some water leaks must be tested for a considerable length of time to become apparent. When a leak appears, find
the highest point of the water track or drop. The highest point usually will show the point of entry. After leak point
has been found, repair the leak and water test to verify that the leak has stopped.

Locating the entry point of water that is leaking into a cavity between panels can be difficult. The trapped water may
splash or run from the cavity, often at a distance from the entry point. Most water leaks of this type become appar-
ent after accelerating, stopping, turning, or when on an incline.

MIRROR INSPECTION METHOD

When a leak point area is visually obstructed, use a suitable mirror to gain visual access. A mirror can also be used
to deflect light to a limited-access area to assist in locating a leak point.

BRIGHT LIGHT LEAK TEST METHOD

Some water leaks in the luggage compartment can be detected without water testing. Position the vehicle in a
brightly lit area. From inside the darkened luggage compartment inspect around seals and body seams. If neces-
sary, have a helper direct a drop light over the suspected leak areas around the luggage compartment. If light is
visible through a normally sealed location, water could enter through the opening.

PRESSURIZED LEAK TEST METHOD

When a water leak into the passenger compartment cannot be detected by water testing, pressurize the passenger
compartment and soap test exterior of the vehicle. To pressurize the passenger compartment, close all doors and
windows, start engine, and set heater control to high blower in HEAT position. If engine can not be started, connect
a charger to the battery to ensure adequate voltage to the blower. With interior pressurized, apply dish detergent
solution to suspected leak area on the exterior of the vehicle. Apply detergent solution with spray device or soft
bristle brush. If soap bubbles occur at a body seam, joint, seal or gasket, the leak entry point could be at that
location.

WIND NOISE

Wind noise is the result of most air leaks. Air leaks can be caused by poor sealing, improper body component
alignment, body seam porosity, or missing plugs in the engine compartment or door hinge pillar areas. All body
sealing points should be airtight in normal driving conditions. Moving sealing surfaces will not always seal airtight
under all conditions. At times, side glass or door seals will allow wind noise to be noticed in the passenger com-
partment during high cross winds. Over compensating door or glass adjustments to stop wind noise that occurs
under severe conditions can cause premature seal wear and excessive closing or latching effort. After a repair pro-
cedure has been performed, test vehicle to verify noise has stopped before returning vehicle to use.

VISUAL INSPECTION BEFORE TESTS

Verify that floor and body plugs are in place and body components are aligned and sealed. If component alignment
or sealing is necessary, refer to the appropriate section of this group for proper procedures.

BODY

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ROAD TESTING WIND NOISE

1. Drive the vehicle to verify the general location of the wind noise.

2. Apply 50 mm (2 in.) masking tape in 150 mm (6 in.) lengths along weatherstrips, weld seams or moldings. After

each length is applied, drive the vehicle. If noise goes away after a piece of tape is applied, remove tape, locate,
and repair defect.

POSSIBLE CAUSE OF WIND NOISE

•

Moldings standing away from body surface can catch wind and whistle.

•

Gaps in sealed areas behind overhanging body flanges can cause wind-rushing sounds.

•

Misaligned movable components.

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Missing or improperly installed plugs in pillars.

•

Weld burn through holes.

STANDARD PROCEDURE

PLASTIC BODY PANEL REPAIR

There are many different types of plastics used in today’s automotive environment. We group plastics in three dif-
ferent categories: Rigid, Semi-Rigid, and Flexible. Any of these plastics may require the use of an adhesion pro-
moter for repair. These types of plastic are used extensively on DaimlerChrysler Motors vehicles. Always follow
repair material manufacturer’s plastic identification and repair procedures.

Rigid Plastics:

Examples of rigid plastic use: Fascias, Hoods, Doors, and other Body Panels, which include SMC, ABS, and Poly-
carbonates.

Semi-Rigid Plastics:

Examples of semi-rigid plastic use: Interior Panels, Under Hood Panels, and other Body Trim Panels.

Flexible Plastics:

Examples of flexible plastic use: Fascias, Body Moldings, and upper and lower Fascia Covers.

Repair Procedure:

The repair procedure for all three categories of plastics is basically the same. The one difference is the material
used for the repair. The materials must be specific for each substrate, rigid repair material for rigid plastic repair,
semi-rigid repair material for semi-rigid plastic repair and flexible repair material for flexible plastic repair.

Adhesion Promoter/Surface Modifier:

Adhesion Promoters/Surface Modifiers are required for certain plastics. All three categories may have plastics that
require the use of adhesion promoter/surface modifiers. Always follow repair material manufacturer’s plastic identi-
fication and repair procedures.

SAFETY PRECAUTION AND WARNINGS

WARNING:

•

Eye protection should be used when servicing components. Personal injury can result.

•

Use an OSHA approved breathing mask when mixing epoxy, grinding, and spraying paint or solvents in

a confined area. Personal injury can result.

•

Avoid prolonged skin contact with resin, petroleum, or alcohol based solvents. Personal injury can

result.

•

Do not venture under a hoisted vehicle that is not properly supported on safety stands. Personal injury

can result.

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