service DODGE HORNET 2023 Repair Manual

SERVICING AND MAINTENANCE235
Coolant Level
The coolant expansion bottle provides a quick visual
method for determining that the coolant level is adequate.
With the engine off and cold, the level of the engine
coolant (antifreeze) in the bottle should be between the
“MIN” and “MAX” marks.
As long as the engine operating temperature is
satisfactory, the coolant bottle need only be checked once
a month.
When additional engine coolant is needed to maintain the
proper level, it should be added to the coolant bottle.
Do not overfill.
Engine Coolant Level — 2.0L
With the engine OFF and cold, the level of the engine
coolant should be within the OK range between the
ADD and FULL range on the dipstick.

1. Remove the cap with level dipstick from the engine
coolant bottle.

2. Clean off the coolant from the dipstick.
3. Rest the cap on the opening of the coolant bottle without tightening the cap.
4. Remove the cap with dipstick and check the coolant level on the dipstick.
The radiator normally remains completely full, so there is
no need to remove the radiator/coolant pressure cap
unless checking for engine coolant freeze point or
replacing coolant. Advise your service attendant of this. As
long as the engine operating temperature is satisfactory,
the coolant bottle need only be checked once a month.
When additional engine coolant is needed to maintain the
proper level, only OAT coolant that meets the
requirements of the manufacturer Material Standard
MS.90032 should be added to the coolant bottle.
Do not overfill.
Cooling System Notes
NOTE:When the vehicle is stopped after a few miles/kilometers
of operation, you may observe vapor coming from the front
of the engine compartment. This is normally a result of
moisture from rain, snow, or high humidity accumulating on the radiator and being vaporized when the thermostat
opens, allowing hot engine coolant (antifreeze) to enter
the radiator.
If an examination of your engine compartment shows no
evidence of radiator or hose leaks, the vehicle may be
safely driven. The vapor will soon dissipate.

Do not overfill the coolant expansion bottle.
 Check the coolant freeze point in the radiator and in
the coolant expansion bottle. If engine coolant needs
to be added, the contents of the coolant expansion
bottle must also be protected against freezing.
 If frequent engine coolant additions are required, the
cooling system should be pressure tested for leaks.
 Maintain engine coolant concentration at a minimum
of 50% OAT coolant (conforming to MS.90032) and
distilled water for proper corrosion protection of your
engine which contains aluminum components.
 Make sure that the coolant expansion bottle overflow
hoses are not kinked or obstructed.
 Keep the front of the radiator clean. If your vehicle is
equipped with air conditioning, keep the front of the
condenser clean.
 Do not change the thermostat for Summer or Winter
operation. If replacement is ever necessary, install
ONLY the correct type thermostat. Other designs may
result in unsatisfactory engine cooling performance,
poor gas mileage, and increased emissions.
WARNING!
Do not open a hot engine cooling system. Never add
engine coolant (antifreeze) when the engine is over -
heated. Do not loosen or remove the cap to cool an
overheated engine. Heat causes pressure to build up
in the cooling system. To prevent scalding or injury,
do not remove the pressure cap while the system is
hot or under pressure.
 Do not use a pressure cap other than the one speci -
fied for your vehicle. Personal injury or engine
damage may result.
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236SERVICING AND MAINTENANCE
BRAKE SYSTEM
In order to ensure brake system performance, all brake
system components should be inspected periodically.
For the proper maintenance intervals
Úpage 224.
Brake Master Cylinder
The fluid in the master cylinder should be checked when
performing under hood services or immediately if the
Brake Warning Light is illuminated.
Be sure to clean the top of the master cylinder area before
removing the cap. If necessary, add fluid to bring the fluid
level up to the requirements described on the brake fluid
reservoir. With disc brakes, fluid level can be expected to
fall as the brake pads wear. Brake fluid level should be
checked when pads are replaced. However, low fluid level
may be caused by a leak and a checkup may be needed.
Use only the manufacturer recommended brake fluid
Úpage 269.
AUTOMATIC TRANSMISSION —
I
F EQUIPPED
Special Additives
It is strongly recommended against using any special
additives in the transmission. Automatic Transmission
Fluid (ATF) is an engineered product and its performance
may be impaired by supplemental additives. Therefore, do
not add any fluid additives to the transmission. Avoid
using transmission sealers as they may adversely affect
seals.
Fluid Level Check
The fluid level is preset at the factory and does not require
adjustment under normal operating conditions. Routine
fluid level checks are not required; therefore the
transmission has no dipstick. An authorized dealer can
check your transmission fluid level using special service
tools. If you notice fluid leakage or transmission
malfunction, visit an authorized dealer immediately to
have the transmission fluid level checked. Operating the
vehicle with an improper fluid level can cause severe
transmission damage.
WARNING!
Riding the brakes can lead to brake failure and possibly
a collision. Driving with your foot resting or riding on the
brake pedal can result in abnormally high brake
temperatures, excessive lining wear, and possible brake
damage. You would not have your full braking capacity
in an emergency.
WARNING!
 Use only the manufacturer recommended brake fluid Úpage 269. Using the wrong type of brake fluid can
severely damage your brake system and/or impair its
performance. The proper type of brake fluid for your
vehicle is also identified on the original factory
installed hydraulic master cylinder reservoir.
 To avoid contamination from foreign matter or
moisture, use only new brake fluid or fluid that has
been in a tightly closed container. Keep the master
cylinder reservoir cap secured at all times. Brake
fluid in an open container absorbs moisture from the
air resulting in a lower boiling point. This may cause
it to boil unexpectedly during hard or prolonged
braking, resulting in sudden brake failure.
This could result in a collision.
 Overfilling the brake fluid reservoir can result in
spilling brake fluid on hot engine parts, causing the
brake fluid to catch fire. Brake fluid can also damage
painted and vinyl surfaces, care should be taken to
avoid its contact with these surfaces.
 Do not allow petroleum-based fluid to contaminate
the brake fluid. Brake seal components could be
damaged, causing partial or complete brake failure.
This could result in a collision.
CAUTION!
Do not use chemical flushes in your transmission as the
chemicals can damage your transmission components.
Such damage is not covered by the New Vehicle Limited
Warranty.

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SERVICING AND MAINTENANCE237
Fluid And Filter Changes
Under normal operating conditions, the fluid installed at
the factory will provide satisfactory lubrication for the life
of the vehicle.
Routine fluid and filter changes are not required. However,
change the fluid and filter if the fluid becomes
contaminated (with water, etc.), or if the transmission is
disassembled for any reason.
Selection Of Lubricant
It is important to use the proper transmission fluid to
ensure optimum transmission performance and life.
Use only the manufacturer specified transmission fluid
Úpage 269. It is important to maintain the transmission
fluid at the correct level using the recommended fluid.
NOTE:No chemical flushes should be used in any transmission;
only the approved lubricant should be used.
FUSES
General Information
The fuses protect electrical systems against excessive
current.
When a device does not work, you must check the fuse
element inside the blade fuse for a break/melt.
Also, please be aware that using power outlets for
extended periods of time with the engine off may result in
vehicle battery discharge.

Blade Fuses

CAUTION!
If a transmission fluid leak occurs, visit an authorized
dealer immediately. Severe transmission damage may
occur. An authorized dealer has the proper tools to
adjust the fluid level accurately.
CAUTION!
Using a transmission fluid other than the manufacturer
recommended fluid may cause deterioration in
transmission shift quality and/or torque converter
shudder. For fluid specifications
Úpage 269.
WARNING!

When replacing a blown fuse, always use an appro -
priate replacement fuse with the same amp rating as
the original fuse. Never replace a fuse with another
fuse of higher amp rating. Never replace a blown
fuse with metal wires or any other material. Do not
place a fuse inside a circuit breaker cavity or vice
versa. Failure to use proper fuses may result in
serious personal injury, fire and/or property damage.
 Before replacing a fuse, make sure that the ignition
is off and that all the other services are switched off
and/or disengaged.
 If the replaced fuse blows again, contact an autho -
rized dealer.
 If a general protection fuse for safety systems
(air bag system, braking system), power unit systems
(engine system, transmission system) or steering
system blows, contact an authorized dealer.
1 — Fuse Element
2 — Blade Fuse with a good/functional fuse element
3 — Blade Fuse with a bad/not functional fuse element
(blown fuse)
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246SERVICING AND MAINTENANCE
BULB REPLACEMENT
Replacement Bulbs, Names, And Part
Numbers
In the instance a bulb needs to be replaced, this section
includes bulb description and replacement part numbers.
Interior Bulbs
The Interior lights are LED, for replacement of any
LED lamps, see an authorized dealer.
Exterior Bulbs
The exterior lights are LED, for replacement of any
LED lamps, see an authorized dealer.
TIRES
TIRE SAFETY INFORMATION
Tire safety information will cover aspects of the following
information: Tire Markings, Tire Identification Numbers,
Tire Terminology and Definitions, Tire Pressures, and
Tire Loading.
Tire Markings

Tire Markings

NOTE:
P (Passenger) — Metric tire sizing is based on US design
standards. P-Metric tires have the letter “P” molded
into the sidewall preceding the size designation.
Example: P215/65R15 95H.
 European — Metric tire sizing is based on European
design standards. Tires designed to this standard have
the tire size molded into the sidewall beginning with the
section width. The letter "P" is absent from this tire size
designation. Example: 215/65R15 96H.
 LT (Light Truck) — Metric tire sizing is based on US
design standards. The size designation for LT-Metric
tires is the same as for P-Metric tires except for the
letters “LT” that are molded into the sidewall preceding
the size designation. Example: LT235/85R16.
 Temporary spare tires are designed for temporary
emergency use only. Temporary high pressure compact
spare tires have the letter “T” or “S” molded into the
sidewall preceding the size designation.
Example: T145/80D18 103M.
 High flotation tire sizing is based on US design stan -
dards and it begins with the tire diameter molded into
the sidewall. Example: 31x10.5 R15 LT.
1 — US DOT Safety Standards
Code (TIN)
2 — Size Designation
3 — Service Description
4 — Maximum Load
5 — Maximum Pressure
6 — Treadwear, Traction and
Temperature Grades

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248SERVICING AND MAINTENANCE
Service Description:
95 = Load Index
 A numerical code associated with the maximum load a tire can carry
H = Speed Symbol
 A symbol indicating the range of speeds at which a tire can carry a load corresponding to its load index under certain operating conditions
 The maximum speed corresponding to the speed symbol should only be achieved under specified operating conditions (i.e., tire pressure, vehicle loading, road conditions, and
posted speed limits)
Load Identification:
Absence of the following load identification symbols on the sidewall of the tire indicates a Standard Load (SL) tire:
 XL = Extra load (or reinforced) tire, or
 LL = Light load tire or
 C, D, E, F, G = Load range associated with the maximum load a tire can carry at a specified pressure
Maximum Load – Maximum load indicates the maximum load this tire is designed to carry
Maximum Pressure – Maximum pressure indicates the maximum permissible cold tire inflation pressure for this tire
EXAMPLE:

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SERVICING AND MAINTENANCE255
Example: If garage temperature = 68°F (20°C) and the
outside temperature = 32°F (0°C) then the cold tire
inflation pressure should be increased by 3 psi (21 kPa),
which equals 1 psi (7 kPa) for every 12°F (7°C) for this
outside temperature condition.
Tire pressure may increase from 2 to 6 psi (13 to 40 kPa)
during operation. DO NOT reduce this normal pressure
buildup or your tire pressure will be too low.
Tire Pressures For High Speed Operation
The manufacturer advocates driving at safe speeds and
within posted speed limits. Where speed limits or
conditions are such that the vehicle can be driven at high
speeds, maintaining correct tire inflation pressure is very
important. Increased tire pressure and reduced vehicle
loading may be required for high-speed vehicle operation.
Refer to an authorized tire dealer or original equipment
vehicle dealer for recommended safe operating speeds,
loading and cold tire inflation pressures.
Radial Ply Tires
Tire Repair
If your tire becomes damaged, it may be repaired if it
meets the following criteria:
The tire has not been driven on when flat.
 The damage is only on the tread section of your tire
(sidewall damage is not repairable).
 The puncture is no greater than ¼ of an inch (6 mm).
Consult an authorized tire dealer for tire repairs and
additional information.
Damaged Run Flat tires, or Run Flat tires that have
experienced a loss of pressure should be replaced
immediately with another Run Flat tire of identical size and
service description (Load Index and Speed Symbol).
Replace the tire pressure sensor as well as it is not
designed to be reused.
Run Flat Tires — If Equipped
Run Flat tires allow you the capability to drive 50 miles
(80 km) at 50 mph (80 km/h) after a rapid loss of inflation
pressure. This rapid loss of inflation is referred to as the
Run Flat mode. A Run Flat mode occurs when the tire
inflation pressure is at or below 14 psi (96 kPa). Once a Run Flat tire reaches the Run Flat mode it has
limited driving capabilities and needs to be replaced
immediately. A Run Flat tire is not repairable. When a Run
Flat tire is changed after being driven under a Run Flat
mode 14 psi (96 kPa) condition, please replace the TPMS
sensor as it is not designed to be reused.
NOTE:TPMS sensor must be replaced after driving the vehicle on
a flat tire condition.
It is not recommended to drive a vehicle loaded at full
capacity or to tow a trailer while a tire is in the Run Flat
mode.
For more information
Úpage 165.
Tire Spinning
When stuck in mud, sand, snow, or ice conditions, do not
spin your vehicle's wheels above 30 mph (48 km/h) or for
longer than 30 seconds continuously without stopping
Úpage 219.WARNING!
High speed driving with your vehicle under maximum
load is dangerous. The added strain on your tires could
cause them to fail. You could have a serious collision.
Do not drive a vehicle loaded to the maximum capacity
at continuous speeds above 75 mph (120 km/h).
WARNING!
Combining radial ply tires with other types of tires on
your vehicle will cause your vehicle to handle poorly.
The instability could cause a collision. Always use radial
ply tires in sets of four. Never combine them with other
types of tires.
WARNING!
Fast spinning tires can be dangerous. Forces generated
by excessive wheel speeds may cause tire damage or
failure. A tire could explode and injure someone.
Do not spin your vehicle's wheels faster than 30 mph
(48 km/h) for more than 30 seconds continuously
when you are stuck, and do not let anyone near a
spinning wheel, no matter what the speed.8

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256SERVICING AND MAINTENANCE
Tread Wear Indicators
Tread wear indicators are in the original equipment tires to
help you in determining when your tires should be
replaced.

Tire Tread

These indicators are molded into the bottom of the tread
grooves. They will appear as bands when the tread depth
becomes 1/16 of an inch (1.6 mm). When the tread is
worn to the tread wear indicators, the tire should be
replaced
Úpage 256.
Life Of Tire
The service life of a tire is dependent upon varying factors
including, but not limited to:
Driving style.
 Tire pressure - Improper cold tire inflation pressures
can cause uneven wear patterns to develop across the
tire tread. These abnormal wear patterns will reduce
tread life, resulting in the need for earlier tire replace -
ment.
 Distance driven.
 Performance tires, tires with a speed rating of V or
higher, and Summer tires typically have a reduced
tread life. Rotation of these tires per the vehicle sched-
uled maintenance is highly recommended.
NOTE:The Wheel Valve Stem must be replaced as well when
installing new tires due to wear and tear in existing tires. Keep dismounted tires in a cool, dry place with as little
exposure to light as possible. Protect tires from contact
with oil, grease, and gasoline.
Replacement Tires
The tires on your new vehicle provide a balance of many
characteristics. They should be inspected regularly for
wear and correct cold tire inflation pressures. The
manufacturer strongly recommends using tires equivalent
to the originals in size, quality and performance when
replacement is needed
Úpage 256. Refer to the Tire And
Loading Information Placard or the Vehicle Certification
Label for the size designation of your tire. The Load Index
and Speed Symbol for your tire will be found on the original
equipment tire sidewall.
For more information relating to the Load Index and Speed
Symbol of a tire
Úpage 246.
It is recommended to replace the two front tires or two rear
tires as a pair. Replacing just one tire can seriously affect
your vehicle’s handling. If you ever replace a wheel, make
sure that the wheel’s specifications match those of the
original wheels.
It is recommended you contact an authorized tire dealer or
original equipment dealer with any questions you may
have on tire specifications or capability. Failure to use
equivalent replacement tires may adversely affect the
safety, handling, and ride of your vehicle.
1 — Tread Wear IndicatorsWARNING!
Tires and the spare tire should be replaced after
six years, regardless of the remaining tread. Failure to
follow this warning can result in sudden tire failure.
You could lose control and have a collision resulting in
serious injury or death.

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258SERVICING AND MAINTENANCE
SPARE TIRES — IF EQUIPPED
NOTE:For vehicles equipped with Tire Service Kit instead of a
spare tire Úpage 211.
For restrictions when towing with a spare tire designated
for temporary emergency use
Úpage 124.
Spare Tire Matching Original Equipped Tire
And Wheel — If Equipped
Your vehicle may be equipped with a spare tire and wheel
equivalent in look and function to the original equipment
tire and wheel found on the front or rear axle of your
vehicle. This spare tire may be used in the tire rotation for
your vehicle. If your vehicle has this option, refer to an
authorized tire dealer for the recommended tire rotation
pattern.
Compact Spare Tire — If Equipped
The compact spare is for temporary emergency use only.
You can identify if your vehicle is equipped with a compact
spare by looking at the spare tire description on the
Tire And Loading Information Placard located on the
driver’s side door opening or on the sidewall of the tire.
Compact spare tire descriptions begin with the
letter “T” or “S” preceding the size designation.
Example: T145/80D18 103M.
T, S = Temporary Spare Tire
Since this tire has limited tread life, the original equipment
tire should be repaired (or replaced) and reinstalled on
your vehicle at the first opportunity.
Do not install a wheel cover or attempt to mount a
conventional tire on the compact spare wheel, since the
wheel is designed specifically for the compact spare tire.
Do not install more than one compact spare tire and wheel
on the vehicle at any given time.
Full-Size Spare — If Equipped
The Full-Size spare is for temporary emergency use only.
This tire may look like the originally equipped tire on the
front or rear axle of your vehicle, but it is not. This spare
tire may have limited tread life. When the tread is worn to
the tread wear indicators, the temporary use Full-Size
spare tire needs to be replaced. Since it is not the same as
your original equipment tire, replace (or repair) the original
equipment tire and reinstall on the vehicle at the first
opportunity.
Limited Use Spare — If Equipped
The limited use spare tire is for temporary emergency use
only. This tire is identified by a label located on the limited
use spare wheel. This label contains the driving limitations
for this spare. This tire may look like the original equipped
tire on the front or rear axle of your vehicle, but it is not.
Installation of this limited use spare tire affects vehicle
handling. Since it is not the same as your original
equipment tire, replace (or repair) the original equipment
tire and reinstall on the vehicle at the first opportunity.
CAUTION!
Because of the reduced ground clearance, do not take
your vehicle through an automatic car wash with a
compact or limited use temporary spare installed.
Damage to the vehicle may result.
WARNING!
Compact and collapsible spares are for temporary
emergency use only. With these spares, do not drive
more than 50 mph (80 km/h). Temporary use spares have limited tread life. When the tread is worn to the
tread wear indicators, the temporary use spare tire
needs to be replaced. Be sure to follow the warnings,
which apply to your spare. Failure to do so could result
in spare tire failure and loss of vehicle control.WARNING!
Limited use spares are for emergency use only.
Installation of this limited use spare tire affects vehicle
handling. With this tire, do not drive more than the
speed listed on the limited use spare wheel. Keep
inflated to the cold tire inflation pressures listed on your
Tire And Loading Information Placard located on the
driver’s side B-pillar or the rear edge of the driver’s side
door. Replace (or repair) the original equipment tire at
the first opportunity and reinstall it on your vehicle.
Failure to do so could result in loss of vehicle control.

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260SERVICING AND MAINTENANCE
TIRE ROTATION RECOMMENDATIONS
The tires on the front and rear of your vehicle operate at
different loads and perform different steering, handling,
and braking functions. For these reasons, they wear at
unequal rates.
These effects can be reduced by timely rotation of tires.
The benefits of rotation are especially worthwhile with
aggressive tread designs such as those on On/Off Road
type tires. Rotation will increase tread life, help to
maintain mud, snow, and wet traction levels, and
contribute to a smooth, quiet ride.
For the proper maintenance intervals
Úpage 224. The
reasons for any rapid or unusual wear should be corrected
prior to rotation being performed.
The suggested rotation method is the “forward cross”
shown in the following diagram. This rotation pattern does
not apply to some directional tires that must not be
reversed.

Tire Rotation (Forward Cross)

DEPARTMENT OF TRANSPORTATION
UNIFORM TIRE QUALITY GRADES
The following tire grading categories
were established by the National
Highway Traffic Safety Administration.
The specific grade rating assigned by the
tire's manufacturer in each category is
shown on the sidewall of the tires on
your vehicle. All passenger vehicle tires must conform
to Federal safety requirements in
addition to these grades.
TREADWEAR
The Treadwear grade is a comparative
rating, based on the wear rate of the tire
when tested under controlled conditions
on a specified government test course.
For example, a tire graded 150 would
wear one and one-half times as well on
the government course as a tire graded
100. The relative performance of tires
depends upon the actual conditions of
their use, however, and may depart
significantly from the norm due to
variations in driving habits, service
practices, and differences in road
characteristics and climate.
CAUTION!
Proper operation of four-wheel drive vehicles depends
on tires of equal size, type and circumference on each
wheel. Any difference in tire size can cause damage to
the power transfer unit. Tire rotation schedule should
be followed to balance tire wear.

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SERVICING AND MAINTENANCE261
TRACTION GRADES
The Traction grades, from highest to
lowest, are AA, A, B, and C. These grades
represent the tire's ability to stop on wet
pavement, as measured under
controlled conditions on specified
government test surfaces of asphalt and
concrete. A tire marked C may have poor
traction performance.
TEMPERATURE GRADES
The Temperature grades are A (the
highest), B, and C, representing the tire's
resistance to the generation of heat and
its ability to dissipate heat, when tested
under controlled conditions on a
specified indoor laboratory test wheel. Sustained high temperature can cause
the material of the tire to degenerate
and reduce tire life, and excessive
temperature can lead to sudden tire
failure. The grade C corresponds to a
level of performance, which all
passenger vehicle tires must meet
under the Federal Motor Vehicle Safety
Standard No. 109. Grades B and A
represent higher levels of performance
on the laboratory test wheel, than the
minimum required by law.
STORING THE VEHICLE
If you are storing your vehicle for more than three weeks,
we recommend that you take the following steps to
minimize the drain on your vehicle's battery:

Disconnect the negative cable from battery.
 If your vehicle is equipped with Stop/Start system then
disconnect both the main and supplemental negative
battery cables.
 Any time you store your vehicle or keep it out of service
(i.e., vacation) for two weeks or more, run the air condi -
tioning system at idle for about five minutes in the
fresh air and high blower setting. This will ensure
adequate system lubrication to minimize the possibility
of compressor damage when the system is started
again.
 If assistance is needed to disconnect the battery
system, see an authorized dealer
NOTE:When the vehicle has not been started or driven for at
least 30 days, an “Extended Park Starting Procedure” is
required to start the vehicle
Úpage 80.
WARNING!
The traction grade assigned to this tire is based on
straight-ahead braking traction tests, and does not
include acceleration, cornering, hydroplaning, or peak
traction characteristics.
WARNING!
The temperature grade for this tire is established for a
tire that is properly inflated and not overloaded.
Excessive speed, underinflation, or excessive loading,
either separately or in combination, can cause heat
buildup and possible tire failure.
CAUTION!
Before removal of the positive and negative terminals
to the battery, wait at least a minute with ignition switch
in the OFF position and close the driver’s door. When
reconnecting the positive and negative terminals to the
battery be sure the ignition switch is in the OFF position
and the driver’s door is closed.
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