Frames & Bumpers: Removal & Installation Dodge Caliber I

INSTALLATION

1. Install fasteners (2) and torque to 23 N.m (204 in. lbs.).
2. Connect wire connector (2) and install horn (1). Refer to «INSTALLATION»(ref-284905-S11519797742008051600000) .
3. Install wiring harness push pin.
4. Install wire connector (1) to bumper reinforcement.
5. Install front fascia. See «INSTALLATION»(ref-284873-S06220431002008051600000) .

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1. Remove splash shield. Refer to «REMOVAL»(ref-284864-S21928672772008051600000) .
2. Remove left and right side fastener (1) located in the wheel well.
3. Remove three fasteners (2) located at the bottom of fascia.
4. Remove middle fasteners (8) located on the top of the fascia.
5. If equipped, disconnect fog lamps (1).
6. Remove two fasteners located at the top of fascia (7).
7. Carefully, remove fascia from vehicle.

1. Lift fascia (2) and fasten both sides of fascia notch (3) onto push pin (6).
2. Install fasteners (1) located inside wheel well up through fascia.
3. Install fascia fasteners (7).
4. Install fascia fasteners (8) through fascia.
5. If equipped, connect wire harness (5) to fog lamp (4).
6. Raise vehicle.
7. Install push pins into locations (1).
8. Install fasteners (2).

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1. Remove push pins (5) from holes (1) located on vehicle (2).
2. Remove rear splash shields.
3. Remove both left (7) and right screws (4).
4. Remove fascia from push pins (10).

1. Raise fascia (6) and hang fascia onto push pins (10).
2. Install push pins (5) into push pin locations (1).
3. Install left (7) and right (4) screws into their respective locations.
4. Install splash shields.

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1. Remove rear fascia. See «REMOVAL»(ref-284873-S34429404632008051600000) .
2. Remove seven bumper reinforcement nuts (1).
3. Remove bumper reinforcement (2).

1. Place bumper reinforcement (2) up to frame locations.
2. Install seven nuts (1) and tighten to 23 N.m (204 in. lbs.)
3. Install fascia. See «INSTALLATION»(ref-284873-S17382804752008051600000) .

FRONT FRAME RAIL TIP REPLACEMENT

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1. Before proceeding with this repair procedure review the required service warnings and precautions. See «WARNING»(ref-284873-S22955822212008051600000) .
2. Disconnect and isolate the battery negative cable. 1 - FESM STRUCTURE 2 - RIGHT SIDE FRAME RAIL 3 - FESM STRUCTURE 4 - LEFT SIDE FRAME RAIL 5 - FRONT RAIL CAP PANEL (TYPICAL BOTH SIDES) 6 - LOWER RADIATOR CROSSMEMBER
3. With vehicle mounted to appropriate pulling and 3-dimensional measuring equipment, complete the following procedure paying particular attention to body dimensions while fitting and welding panels.
4. Remove bumper components, cooling module, headlamp, and all other components for clear access to repair area.
5. Remove front rail cap panel (5) on damaged rail.
6. Remove welds holding lower radiator crossmember (6) to damaged rail (if crossmember is damaged, remove completely).
7. Remove welds holding FESM structure (1 and 3) to rail (if damaged, remove complete assembly).

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1. On inner rail (1), mark at 50 mm (2 in) (4) forward of the leading edge of flanged hole in rail.
2. On outer rail (3), continue mark (2) from inner rail.

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1. On inner rail (4), mark at 80 mm (3.2 in) (1) forward of centerline of rear battery tray weld-nut (located on top of rail).
2. On outer rail (3), continue mark (2) from inner rail (4).
3. Mark replacement part in same location.
4. On left rail (2), remove bracket (1) located on inner rail. 1 - CUT EXISTING PARTS ON FORWARD SIDE OF SCRIBED LINE 2 - LEFT SIDE 3 - RIGHT SIDE
5. Using a cut-off wheel, reciprocating saw, or equivalent: Cut all existing parts on the forward side of the scribe line (1) using care not to damage the material that will not be removed. Right rail section location: When installation of new tip is complete, there is a 6 mm (0.25 in) hole on the inner rail at the forward edge of the section joint which may need to be recreated or restored. Left rail section location: When installation of new tip is complete, there is a 10 mm (0.40 in) hole in bottom horizontal surface of rail which may need to be restored. Cut all replacement parts on the rearward side of the scribe line again using care not to make any additional damage but do not discard any material yet.
6. Clean all sharp edges and create a slight taper for weld purposes. 1 - CUT OFF FLANGES 2 - CUT, REMOVE AND SAVE THESE PIECES (WELD BACKERS) 3 - CUT OFF FLANGES 4 - INNER RAIL 5 - CUT STRIP 19 mm (0.75 in) 6 - CUT STRIP 19 mm (0.75 in) 7 - OUTER RAIL
7. From the remaining replacement part, cut a 19 mm (0.75 in) strip (2) from both the inner and outer rail. Clip off the weld flanges (1 and 3), top and bottom, and dress edges. These pieces will be the weld-backer.
8. Prepare welding equipment per the weld chart at the end of procedure. See «SPECIFICATIONS»(ref-284873-S16191105252008051600000) . 1 - FRAME RAIL 2 - WELD BACKERS 3 - REPLACEMENT FRAME RAIL TIP
9. Install the weld-backers (2) into the frame rail (1), centering them on cut edge. Clamp and tack the weld-backers in position when proper fit is confirmed.
10. Dry fit the new rail tip (3) to verify alignment, fit and make any adjustments as necessary. NOTE: Any burned surface coatings will need to be removed prior to application of corrosion preventative coatings. CAUTION: Shield the surrounding area and components from exposure to the welding spatter and heat.
11. Using the appropriate measuring equipment, verify the front frame rail tip's location in all three (X, Y and Z) planes of space, and adjust if required. See «SPECIFICATIONS»(ref-284873-S16191105252008051600000) .
12. Weld using a skip-stitch method until the full length of the joint is completed on both the inner and outer rail. To avoid excessive heat buildup, move between inner and outer rail during welding.
13. Dress welds without removing any base material paying particular attention to the mounting surface of the outer rail.
14. Install the bracket removed from the left rail. 1 - FESM STRUCTURE 2 - CLEAN AND REFINISH REPAIRED AREAS 3 - FESM STRUCTURE 4 - LEFT SIDE FRAME RAIL 5 - FRONT RAIL CAP PANEL 6 - RIGHT SIDE FRAME RAIL 7 - LOWER RADIATOR CROSSMEMBER
15. Either install new or reposition the lower radiator crossmember (7) and FESM structure (1 and 3) and clamp in place and weld.
16. Install new front rail cap panel (5).
17. Clean all repaired areas and apply appropriate refinish and corrosion protection materials.

1. Install the fore/aft crossmember and install the engine anti-roll mount (3) through bolt (2).
2. Install the bolts (1, 2 and 3), and tighten using the following sequence: Tighten the bolt (1) to 78 N.m (58 ft. lbs.). Tighten the bolt (2) to 78 N.m (58 ft. lbs.). Tighten the bolt (3) to 129 N.m (95 ft. lbs.).
3. Tighten the bolt (2) to 65 N.m (48 ft. lbs.).
4. If equipped, install the belly pan.
5. Install the three front screws (4), the three rear screws (2) and on push pin fastener into the center of the belly pan.

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1. Raise and support the vehicle. Refer to «STANDARD PROCEDURE»(ref-284865-S38818398862008051600000) .
2. Remove the four wheel well screws.
3. If equipped, remove the three front screws (4), the three rear screws (2) and one push pin fastener from the center of the belly pan.
4. Remove the rear roll mount (4) through bolt (2).
5. Remove the three bolts (3) attaching the rear roll mount (5) to the crossmember and remove the mount.
6. Remove the for/aft crossmember (4). See «REMOVAL»(ref-284873-S05265399822008051600000) .
7. Remove the front wheels (1). Refer to «REMOVAL»(ref-284870-S10878613282008051600000) .
8. Remove the lower ball joint (6) pinch bolts (4) and nuts (5).
9. Remove the bolt attaching the pressure line routing bracket to the steering gear.
10. Remove the bolt attaching the return line to the crossmember.
11. Remove the sway bar bushing bolts (1) and support the sway bar (2) up in the vehicle.
12. Remove the steering gear mounting bolts (1) and support the steering gear (2) up in the vehicle.
13. Mark the crossmember (3) to body location (1) using a grease pencil (2) or equivalent.
14. Support the crossmember with a suitable lifting device.
15. Remove the crossmember bolts (1 and 2) and lower the crossmember from the vehicle.
16. Remove the lower control arm (3) front pivot bolts (2).
17. Remove the lower control arm rear pivot bolts (3) and separate the lower control arms from the crossmember (1).

1. Install the lower control arms and install the rear pivot bolts (3).
2. Install the front pivot bolts (2).
3. Support the crossmember on a suitable lifting device.
4. Raise the crossmember into position onto the vehicle.
5. Install the bolts (1 and 2) and align the engine cradle to the marks made during removal.
6. Tighten the bolts to 150 N.m (111 ft. lbs.).
7. Position the steering gear back into place and install the bolts (1).
8. Tighten the bolts to 70 N.m (52 ft. lbs.).
9. Position the stabilizer bar (2) back into place and install the bushing bolts (1).
10. Tighten the bolts to 61 N.m (45 ft. lbs.).
11. Position the power steering lines back into place and install the support bracket (2) bolts (1).
12. Tighten the bolts to 8 N.m (70 ft. lbs.).
13. Connect the lower ball joint stud (6) to the knuckle (3).
14. Install a NEW ball joint stud pinch bolt (4) and nut (5). Tighten the nut to 82 N.m (60 ft. lbs.).
15. Install the fore/aft crossmember (4). See «INSTALLATION»(ref-284873-S21267366482008051600000) .
16. Install the front wheels (1). Refer to «INSTALLATION»(ref-284870-S38305511352008051600000) .
17. With the full weight of the vehicle on the suspension tighten the front control arm bushing bolts to 123 N.m (91 ft. lbs.)
18. Perform wheel alignment as necessary. Refer to «STANDARD PROCEDURE»(ref-284868-S42699248442008051600000) .
19. Install the rear roll mount (4) and install the three bolts (3) attaching it to the crossmember.
20. Tighten the bolts (3) to 153 N.m (112 ft. lbs.).
21. Install the through bolt (2) and tighten to 65 N.m (48 ft. lbs.).
22. If equipped, install the belly pan.
23. Install the three front screws (4), the three rear screws (2) and push pin fasteners into the center of the belly pan.

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1. Remove the park brake shoes. Refer to «REMOVAL»(ref-284869-S15163699552008051600000) .
2. Park brake cable from lever.
3. Remove the hair pin clip and separate the brake cable (2) from the backing plate (3).
4. Remove the bolt (2) and separate the brake line (1) from the trailing arm (3).
5. Remove the bolt (1), the clip (2) and separate the brake line (3) from the trailing arm.
6. Separate the wheel speed sensors and position aside as necessary to remove the crossmember. Refer to «REMOVAL»(ref-284886-S17250194402008051600000) .
7. If equipped, remove the rear drive module. Refer to «REMOVAL»(ref-284872-S07837852422008051600000) .
8. Remove the cotter pins (2), the nuts (3) and the washers (4).
9. Remove both half shafts.
10. Remove the lower strut bolts.
11. Remove the trailing link bushing bolts.
12. Support the rear cradle with a suitable lifting device.
13. Remove the rear cradle bolts and lower the cradle assembly from vehicle.
14. Remove the lower stabilizer link nuts (2).
15. Remove the lower link bolts (5 and 6) at the cradle.
16. Remove the upper link bolts (2) at the cradle.
17. Remove the toe link cam bolts (1) at the cradle.
18. Remove the suspension knuckle assemblies.
19. Remove the stabilizer bushing bolts (1) and separate the stabilizer bar from the cradle.

1. Install the stabilizer bar and install the bushings and bolts (1).
2. Tighten the bolts to 61 N.m (45 ft. lbs.).
3. Position the suspension knuckle assemblies back into position onto the crossmember.
4. Install the toe link cam bolts (1) at the cradle.
5. Tighten the bolts to 35 N.m (26 ft. lbs.).
6. Install the upper link bolts (2) at the cradle.
7. Tighten the bolts to 90 N.m (70 ft. lbs.).
8. Install the lower link bolts (5 and 6) at the cradle.
9. Tighten the bolts to 90 N.m (70 ft. lbs.).
10. Install the stabilizer link nuts (2).
11. Tighten the nuts to 58 N.m (43 ft. lbs.).
12. Support the rear cradle assembly (1) with a suitable lifting device and position back into the vehicle.
13. Install the cradle bolts (2 and 3): Tighten the front bolts (2) first to 110 N.m (81 ft. lbs.). Tighten the rear bolts (3) next to 110 N.m (81 ft. lbs.).
14. Install the trailing link (1) bushing bolts (2 and 3): Tighten the inboard bolts (3) first to 110 N.m (81 ft. lbs.). Tighten the outboard bolts (2) next to 110 N.m (81 ft. lbs.).
15. Install the lower strut bolts (1).
16. Tighten the bolts to 99 N.m 73 ft. lbs.).
17. If equipped, install the rear half shafts.
18. Install the nuts (3) and washers (4).
19. Tighten the nuts to 244 N.m (180 ft. lbs.).
20. Install new cotter pins (2).
21. Install the rear drive module (1). Refer to «INSTALLATION»(ref-284872-S41253021542008051600000) .
22. Install the wheel speed sensor back. Refer to «INSTALLATION»(ref-284886-S02925621672008051600000) .
23. Position the brake lines (3) back into place, connect the clips (2) and install the bolts (1).
24. Tighten the bolts to 15 N.m (11 ft. lbs.).
25. Position the brake lines (1) back into place, and install the bolts (2).
26. Tighten the bolts to 23 N.m (17 ft. lbs.).
27. Install the brake cable (2) onto the backing plate (3) and install the hair pin clip (1).
28. Connect the brake cable to the park brake lever.
29. Install the park brake shoes. Refer to «INSTALLATION»(ref-284869-S11960366682008051600000) .
30. Check and adjust wheel alignment as necessary. Refer to «STANDARD PROCEDURE»(ref-284868-S42699248442008051600000) .