2007 Chrysler/Dodge Caliber Workshop Repair Service Manual (w/ Body Repair manual)

DODGE CALIBER BODY REPAIR MANUAL

SAFETY NOTICE CAUTION ALL SERVICE AND REBUILDING INSTRUCTIONS CONTAINED HEREIN ARE APPLICABLE TO, AND FOR THE CONVENIENCE OF, THE AUTOMOTIVE TRADE ONLY. All test and repair procedures on components or assemblies in non-automotive applications should be repaired in accordance with instructions supplied by the manufacturer of the total product. Proper service and repair is important to the safe, reliable operation of all motor vehicles. The service produces recommended and described in this publication were developed for professional service personnel, and are effective methods for performing vehicle repair. Following these procedures will help ensure efficient economical vehicle per- formance and service reliability. Some service procedures require the use of special tools designed for specific procedures. These special tools should be used as recommended throughout this publication. Special attention should be exercised when working with spring-or tension-loaded fasteners and devices such as E- Clips, Circlips, Snap rings, etc., since careless removal may cause personal injury. Always wear safety goggles when working on vehicles or vehicle components. It is important to note that this publication contains various Cautions and Warnings. These should be read carefully in order to minimize risk of personal injury or the possibility that improper service methods may damage the vehicle or render it unsafe. It is important to note that these Cautions and Warnings cover only the situations and procedures DaimlerChrysler Corporation has encountered and recommended. DaimlerChrysler Corporation cannot possibly know, evaluate, and advise the service trade of all conceivable ways in which service may be performed, or of the possible hazards of each. Consequently, DaimlerChrysler has not undertaken any such broad service review. Accordingly, any- one uses a service procedure or tool that is not recommended in this publication must be certain that neither personal safety, nor vehicle safety, will be jeopardized by the service methods they select. Back to Index

MANUFACTURER ADVERTISEMENTS (CLICK ON LINKS ) • PPG INDUSTRIES • TECH AUTHORITY • DAIMLERCHRYSLER PAINT CONDITION DECK, SEALER SOUND DEADENER REPAIR GUIDE • MOPAR PARTS • DAIMLERCHRYSLER PLASTIC REPAIR GUIDE, WELDING & WELD BONDING MANUAL • HEMI.COM • TEAM PSE FACILITY PLANNING SERVICES Copies of the following Body Repair Manuals are available by calling 1-800-890-4038 • Chrysler 300 (81-316-0531CD) • Jeep Grand Cherokee (81-316-0635-CD) • Dakota (81-316-0634CD) • Pacifica (81-316-0530-CD) • Durango (81-316-0430CD) • PT Convertible (81-316-0531-CD) • Jeep Commander (81-316-0636-CD) • Sprinter Van (81-316-0533-CD) Back to Index

INTRODUCTION Dodge Caliber This manual has been prepared for use by all body technicians involved in the repair of the Dodge Caliber. This manual shows: - Typical unibody panels contained in these vehicles - The types of welds for the panel - The weld locations for these panels - Proper sealer types and correct locations Body Construction Characteristics ............................................................. History of Collision Repair.......................................................................... Corrosion Protection .................................................................................. Vehicle Identification Number Information ................................................. Paint Codes Information ............................................................................ Welded Panel Replacement....................................................................... Sealer Locations ........................................................................................ Structural Adhesive Locations ................................................................... NVH/Structural Foam Locations ................................................................ Sound Deadener Locations ....................................................................... Frame/Body Dimensions ............................................................................ Front Frame Rail Sectioning Procedure .................................................... Additional Support/Information ................................................................... DaimlerChrysler Motors Corporation reserves the right to make improvements in design or to change specifications to these vehicles without incurring any obligation upon itself.

BODY CONSTRUCTION CHARACTERISTICS Definitions of Steels used in the Jeep Compass: MS 66 - Represents an uncoated Hot Rolled Steel Sheet used mainly for interior braces and reinforcements. MS 67 - Represents an uncoated Cold Rolled Sheet structural steel used in areas where structural integrity is critical. EG., the type of steel used for the “A” pillar. MS 264 - Represents an uncoated high strength low alloy (HSLA) steel used in applications where structural integrity is critical. MS 6000-44A - Low carbon, hot dipped galvanneal (or EGA) with 45 g/m² minimum coating weight on both sides. - Most common Sheet Steel product used by Chrysler. MS 6000-44VA - 50 ksi min. yield strength, HSLA, killed steel, with 44 g/m² minimum coating weight on both sides. - Most common high strength coated steel product used by Chrysler. MS 10176 - Boron-alloyed steels ate analogy with 22MnB5 which are matched to the hardening process die. Sheet blanks are heat treated in the furnace on an inert gas or air atmosphere and then formed in the press die and hard- ened at the same time. The boron is produced in two configurations one for use in upper body and one that has hot- dip aluminizated coating for corrosion protection. MS82-1228 - Represent a coated high strength low alloy (HSLA) hot or cold rolled sheet steel used in applictions where structural integrity is critical. PARTIAL LIST OF STEEL APPLICATIONS Galvannealed Steel Body Side Aperture Rear Door - Inner Panel Cowl Plenum Panel Rear Door - Outer Panel Cowl Side Panel Rear Floor Pan Dash Panel Rear Floor Pan Front Crossmember Front Door - Inner Panel Rear Floor Pan Side Rail Front Door - Outer Panel Rear Suspension Crossmember Front Fender Rear Quarter Panel - Inner Front Floor Pan Rear Quarter Panel - Outer Front Hinge Pillar Rear Wheelhouse - Inner Front Rail Roof Panel Front Strut Mounting Tower UpperLoad Path Beam Front Wheelhouse (Front and Rear) Upper Radiator Crossmember Lower Radiator Crossmember Back to Index

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2007 Chrysler/Dodge Caliber Workshop Repair Service Manual (w/ Body Repair manual)

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