Content .. 169 170 171 172 ..

Dodge Caliber. Manual - part 171

CONDITION

POSSIBLE CAUSE

CORRECTION

INADEQUATE AIR CONDITIONER
PERFORMANCE (COOLING
SYSTEM SUSPECTED)

1. Electric radiator fan not operating
when A/C is on.

1. Refer to appropriate Powertrain
Diagnostic Procedures manual for
operation of the DRB III

scan tool.

Repair as necessary.

2. Radiator and/or air conditioning
condenser is restricted, obstructed
or dirty.

2. Remove restriction and/or clean
as necessary.

3. Radiator air seals missing or
improperly installed.

3. Inspect air seals. Repair as
necessary.

4. Engine is overheating (heat may
be transferred from radiator to A/C
condenser). High underhood
temperature due to engine
overheating may also transfer heat
to A/C components.

4. Correct overheating condition.
Refer to this section.

INADEQUATE HEATER
PERFORMANCE

1. Has a diagnostic trouble code
(DTC) been set?

1. Refer to Powertrain Diagnostic
Procedures.

2. Coolant level low.

2. Check cooling system for leaks.
Repair as necessary.

3. Obstructions in heater hose
fittings at engine.

3. Remove heater hoses at both
ends and check for obstructions.
Repair as necessary.

4. Heater hose kinked.

4. Locate kinked area and repair as
necessary.

5. Water pump is not pumping
coolant to heater core. When the
engine is fully warmed up, both
heater hoses should be hot to the
touch.

5. (Refer to 7 - COOLING/ENGINE/
WATER PUMP - DIAGNOSIS AND
TESTING). Repair as necessary.

HEAT ODOR

1. Various heat shields are used at
certain components. One or more
of these shields may be missing.

1. Locate missing shields and
replace or repair as necessary.

2. Is temperature gauge reading
above the normal range?

2. Refer to the previous
Temperature Gauge Reads High in
these Diagnostic Charts. Repair as
necessary.

3. Is cooling fan operating
correctly?

3. Repair as necessary.

4. Has undercoating been applied
to any unnecessary component.

4. Clean undercoating as necessary.

5. Engine may be running rich
causing the catalytic converter to
overheat.

5. Refer to appropriate Powertrain
Diagnostic Procedures manual for
operation of the DRB III

scan tool.

Repair as necessary.

POOR DRIVEABILITY
(THERMOSTAT POSSIBLY STUCK
OPEN). GAUGE MAY BE READING
LOW

1. Has a diagnostic trouble code
(DTC ) been set?

1. Refer to the Powertrain
Diagnostic Procedure manual for
checking a DTC related to the
thermostat.

COOLING

7 - 9

CONDITION

POSSIBLE CAUSE

CORRECTION

STEAM IS COMING FROM FRONT
OF VEHICLE NEAR GRILLE AREA
WHEN WEATHER IS WET,
ENGINE IS WARMED UP,
RUNNING, AND VEHICLE IS
STATIONARY. TEMPERATURE
GAUGE IS IN NORMAL RANGE.

1. During wet weather, moisture
(snow, ice or rain condensation) on
the radiator will evaporate when the
thermostat opens. This opening
allows heated water into the
radiator. When the moisture
contacts the hot radiator, steam
may be emitted. This usually occurs
in cold weather with no fan or
airflow to blow it away.

1. Occasional steam emitting from
this area is normal. No repair is
necessary.

COOLANT COLOR

1. Coolant color is not necessarily
an indication of adequate corrosion
or temperature protection. Do not
rely on coolant color for determining
condition of coolant.

1. Check the freeze point of the
coolant (Refer to 7 - COOLING/
ENGINE/COOLANT - DIAGNOSIS
AND TESTING). Adjust the
glycol-to-water ratio as required.

COOLANT LEVEL CHANGES IN
COOLANT RECOVERY/RESERVE
BOTTLE

1. Level changes are to be
expected as coolant volume
fluctuates with engine temperature.
If the level in the bottle was
between the FULL HOT and ADD
marks at normal engine operating
temperature, the level should return
to within that range after operation
at elevated temperatures.

1. A normal condition. No repair is
necessary.

STANDARD PROCEDURE

ROUTINE COOLANT LEVEL CHECK

NOTE: Do not remove pressure cap for routine coolant level inspections.

The coolant recovery/reserve system provides a quick visual method for determining the coolant level without
removing the radiator cap. Simply observe, with the engine idling and warmed up to normal operating temperature,
that the level of the coolant in the recovery/reserve container is between the FULL HOT and ADD marks.

DRAINING COOLING SYSTEM

WARNING: DO NOT OPEN THE RADIATOR DRAIN-
COCK WITH THE SYSTEM HOT AND UNDER
PRESSURE. SERIOUS BURNS FROM COOLANT
CAN OCCUR.

NOTE: Drain, flush, and fill the cooling system at
the mileage or time intervals specified in the
MAINTENANCE SCHEDULE (Refer to LUBRICA-
TION & MAINTENANCE/MAINTENANCE SCHED-
ULES - DESCRIPTION). If the solution is dirty,
rusty, or contains a considerable amount of sedi-
ment; clean and flush with a reliable cooling sys-
tem cleaner. Care should be taken in disposing of
the used engine coolant from your vehicle. Check
governmental regulations for disposal of used
engine coolant.

7 - 10

COOLING

1. Position a clean collecting container under draincock location.

2. Without removing the pressure cap and with system not under pressure, turn draincock counterclockwise to

open.

3. The coolant reserve bottle should empty first, then remove the pressure cap.

4. If coolant reserve bottle does not empty first:

a. Check condition of the pressure cap and cap seals.

b. Check for kinked/torn overflow hose from filler neck to reserve bottle.

5. Allow cooling system to drain completely.

FILLING COOLING SYSTEM

WARNING: MAKE SURE ENGINE COOLING SYSTEM IS COOL BEFORE REMOVING PRESSURE CAP OR
ANY HOSE. THE COOLING SYSTEM IS PRESSURIZED WHEN HOT. SEVERE PERSONAL INJURY MAY
RESULT FROM ESCAPING HOT COOLANT.

CAUTION: Do not use well water, or suspect water supply in cooling system. A 50/50 mixture of the recom-
mended ethylene glycol and distilled water is recommended. For recommended coolant usage, (Refer to
LUBRICATION & MAINTENANCE/FLUID TYPES - DESCRIPTION).

NOTE: For cooling system capacity (Refer to LUBRICATION & MAINTENANCE/SPECIFICATIONS - FLUID
CAPACITIES).

1. Close radiator draincock. Hand tighten only.

2. Remove cooling system pressure cap. Install

3. Use the supplied clip to pinch overflow hose that connects between the radiator and the coolant recovery con-

tainer.

NOTE: While filling the cooling system, pour coolant into the larger section of the Filling Aid Funnel, Tool
8195.

4. Remove clip from overflow hose and remove Filling Aid Funnel, Tool 8195.

5. Install cooling system pressure cap.

6. Slowly fill the coolant recovery container to the FULL HOT mark with the recommended coolant. It may be nec-

essary to add coolant to the recovery container after one warm-up/cool down cycle in order to maintain the cool-
ant level between the FULL HOT and ADD marks. This is due to the removal of trapped air from the system.

COOLING SYSTEM CLEANING/REVERSE FLUSHING

CLEANING

Drain the cooling system and refill with water. Run the engine with the radiator cap installed until the upper radiator
hose is hot. Stop the engine and drain the water from system. If the water is dirty, fill the system with water, run the
engine and drain the system. Repeat this procedure until the water drains clean.

REVERSE FLUSHING

Reverse flushing of the cooling system is the forcing of water through the cooling system. This is done using air
pressure in the opposite direction of normal coolant flow. It is usually only necessary with very dirty systems with
evidence of partial plugging.

REVERSE FLUSHING RADIATOR

Disconnect the radiator hoses from the radiator inlet and outlet. Attach a section of the radiator hose to the radiator
bottom outlet fitting and insert the flushing gun. Connect a water supply hose and air supply hose to the flushing
gun.

CAUTION: Internal radiator pressure must not exceed 138 kPa (20 psi) as damage to radiator may result.

COOLING

7 - 11

Allow the radiator to fill with water. When the radiator is filled, apply air in short blasts. Allow the radiator to refill
between blasts. Continue this reverse flushing until clean water flows out through the rear of the radiator cooling
tube passages.

REVERSE FLUSHING ENGINE

Drain the cooling system. Remove the thermostat housing and thermostat. Install the thermostat housing. Discon-
nect the radiator upper hose from the radiator and attach the flushing gun to the hose. Disconnect the radiator lower
hose from the water pump and attach a lead-away hose to the water pump inlet fitting.

CAUTION: On vehicles equipped with a heater water control valve, be sure the heater control valve is
closed (heat off). This will prevent coolant flow with scale and other deposits from entering the heater core.

Connect the water supply hose and air supply hose to flushing gun. Allow the engine to fill with water. When the
engine is filled, apply air in short blasts, allowing the system to fill between air blasts. Continue until clean water
flows through the lead away hose.

Remove the lead away hose, flushing gun, water supply hose and air supply hose. Remove the thermostat housing
and install the thermostat. Install the thermostat housing with a replacement gasket. Refer to Thermostat Replace-
ment. Connect the radiator hoses. Refill the cooling system with the correct antifreeze/water mixture (Refer to
LUBRICATION & MAINTENANCE/FLUID TYPES - DESCRIPTION). Refer to Refilling the Cooling System.

CHEMICAL CLEANING

In some instances, use a radiator cleaner (Mopar

Radiator Kleen or equivalent) before flushing. This will soften

scale and other deposits and aid flushing operation.

CAUTION: Follow manufacturers instructions when using these products.

INSPECTION

After performing a cleaning/flush procedure, inspect all hoses, clamps and connections for deterioration and leaks.
Inspect radiator and heater core for leaks.

SPECIFICATIONS

TORQUE

DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.

Bolts, A/C Condenser to Radiator

5.1

–

Bolt, Automatic Belt Tensioner Pulley

–

Bolt Automatic Belt Tension Assembly

–

Bolts, Charge Air Cooler to Radiator (Turbo Equipped)

5.1

–

Bolt, Coolant Recovery Bottle

–

Bolts, Coolant Adapter

12.5

–

110

Bolts, Inlet housing to coolant adapter

Screw, bypass valve to radiator

5.1

Screw, transmission coller to radiator

5.1

Engine Coolant Temperature Sensor -

–

168

Pivot Bolt, Generator Mounting

–

Locking Nut, Generator Mounting

–

Screws, Radiator Fan Shroud to Radiator

–

Screws, Transmission Cooler to Radiator

–

Bolts, Water Pump to Engine Block

–

105

Bolts, Water Pump Inlet Tube to water pump housing

–

212

7 - 12

COOLING

Content .. 169 170 171 172 ..