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Home >> Fiat >> 2014 >> 500c Abarth >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 1 (1.4L Engine - I4 Non-Turbo (Service Information) 500 & 500C) >> Cylinder Head >> Cover(S), Cylinder Head >> Installation >> Installation

Cover(S), Cylinder Head: Installation: Installation

WARNING: This page is about a different variant/trim than selected.
Fig 1: Oil Filler Neck O-Ring
GC0152570Courtesy of CHRYSLER GROUP, LLC
  1. If required, install a new oil filler neck O-ring (1).
    Fig 2: Oil Filler Neck, Oil Filler Neck Lock & Bolt
    GC0152569Courtesy of CHRYSLER GROUP, LLC
  2. If required, install the oil filler neck (1) to the cylinder head cover. Secure the oil filler neck (1) with the oil filler neck lock (2) and bolt (3) tightened to 9 N.m (80 in. lbs.).
    Fig 3: Cylinder Head Cover Gasket & Spark Plug Tube Seals
    GC0152496Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    When servicing components near the vacuum pump, avoid contact with the plastic nipple that connects the vacuum pump to the brake booster hose. It is possible to crack the plastic nipple resulting in a brake booster vacuum leak.

  3. Install the cylinder head cover gasket (1).
  4. The spark plug tube seals (2) can be reused if not damaged.
    Fig 4: Residual Sealant Locations
    GC0152475Courtesy of CHRYSLER GROUP, LLC
  5. Clean the variable valve actuator assembly, camshaft caps, camshaft housing and cylinder head cover mating surfaces with isopropyl alcohol in preparation for sealant application.
    CAUTION:

    Engine assembly requires the use of a unique sealant that is compatible with engine oil. Using a sealant other than Mopar® Engine RTV GEN II may result in engine fluid leakage.

    CAUTION:

    Following the application of Mopar® Engine RTV GEN II to the gasket surfaces, the components must be assembled within 10 minutes and the attaching fasteners must be tightened to specification within the next 10 minutes. Prolonged exposure to the air prior to assembly may result in engine fluid leakage.

  6. Apply a 2 to 3 mm wide bead of Mopar® Engine RTV GEN II sealant (1) to the cylinder head cover T-joints as shown in illustration.
    Fig 5: Cylinder Head Cover & Fuel Rail Blocker Tightening Sequence
    GC0152495Courtesy of CHRYSLER GROUP, LLC
  7. Install the cylinder head cover and fuel rail blocker (1) with twelve bolts. Tighten the twelve bolts in two steps following the sequence shown in illustration:
    • Step 1: All to 5 N.m (44 in. lbs.).
    • Step 2: All to 9 N.m (80 in. lbs.).
    Fig 6: Upper Timing Belt Cover & Bolts
    GC0152466Courtesy of CHRYSLER GROUP, LLC
  8. Install the upper timing belt cover (1) with two bolts (2 and 3) tightened to 9 N.m (80 in. lbs.).
    Fig 7: Intake Manifold Seals
    GC0152454Courtesy of CHRYSLER GROUP, LLC
  9. Install four new intake manifold seals (1).
    Fig 8: Intake Manifold & Fasteners
    GC0152436Courtesy of CHRYSLER GROUP, LLC
  10. Loosely install an intake manifold flange bolt (3) and the support bolt (2) to hold the intake manifold in position.
    Fig 9: Intake Manifold Flange Bolts Tightening Sequence
    GC0152497Courtesy of CHRYSLER GROUP, LLC
  11. Raise and support the vehicle. Refer to HOISTING .
  12. Install the remaining six of the seven intake manifold flange bolts (1). Tighten all seven intake manifold flange bolts in the sequence shown in illustration to 15 N.m (11 ft. lbs.).
    Fig 10: Wire Harness Retainers
    GC0152434Courtesy of CHRYSLER GROUP, LLC
  13. Position the wire harness and close the two wire harness retainers (1).
    Fig 11: Intake Manifold & Fasteners
    GC0152436Courtesy of CHRYSLER GROUP, LLC
  14. Lower the vehicle.
  15. Tighten the intake manifold support bolt (2) to 9 N.m (80 in. lbs.).
    Fig 12: A/C Compressor & Fasteners
    GC0152459Courtesy of CHRYSLER GROUP, LLC
  16. Install the A/C compressor (1). Refer to COMPRESSOR, A/C, INSTALLATION .
    Fig 13: Drive Belt Tensioners & Assembly With Drive Belt Routing
    GC0152365Courtesy of CHRYSLER GROUP, LLC
  17. Install the accessory drive belt (4). Refer to BELT, SERPENTINE, INSTALLATION .
    Fig 14: Right Vertical Brace, Frame Splash Shield & Fasteners
    GC0153366Courtesy of CHRYSLER GROUP, LLC
  18. Install the frame splash shield (3) with three screws (1).
  19. Install two screws (2) to the front wheelhouse splash shield.
  20. Install the right vertical brace (5) with two bolts (4) tightened to 45 N.m (33 ft. lbs.).
    Fig 15: Lower Air Dam/Belly Pan
    GC0082359Courtesy of CHRYSLER GROUP, LLC
  21. Install the belly pan. Refer to BELLY PAN, INSTALLATION .
    Fig 16: Wire Harness Duct & Bolts
    GC0152433Courtesy of CHRYSLER GROUP, LLC
  22. Install the wiring harness duct (1) to the cylinder head cover with two bolts (3) tightened to 9 N.m (80 in. lbs.).
  23. Install the ground lug (2) to the cylinder head cover and tighten the bolt (2) to 9 N.m (80 in. lbs.).
    Fig 17: Ignition Coil, Connector & Bolt
    GC0152564Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Number 1 cylinder ignition coil shown in illustration, all others similar.

  24. Install the ignition coils (1). Refer to COIL, IGNITION, INSTALLATION .
    Fig 18: Oil Separator Housing Bracket & Fasteners
    GC0152568Courtesy of CHRYSLER GROUP, LLC
  25. Install the oil separator housing bracket (1) with two bolts (2) and one nut (3). Tighten the three fasteners to 13 N.m (115 in. lbs.).
    Fig 19: Vacuum Pump & Bolts
    GC0152461Courtesy of CHRYSLER GROUP, LLC
  26. Connect the vacuum line to the vacuum pump (1).
    Fig 20: Electronic Throttle Control, Connector, Clip & Bolts
    GC0152439Courtesy of CHRYSLER GROUP, LLC
  27. Connect and lock the electrical connector (3) to the Electronic Throttle Control (ETC) (4) and engage the ETC harness to the clip (2) on the throttle body.
    Fig 21: Evaporative Emissions Purge Solenoid Connector, Fuel Injector Wire Harness Connector & Fasteners
    GC0152438Courtesy of CHRYSLER GROUP, LLC
  28. Connect and lock the fuel injector wire harness electrical connector (2).
  29. Connect and lock the evaporative emissions purge solenoid electrical connector (1).
    Fig 22: IAT/MAP Sensor, Connector & Bolt
    GC0152437Courtesy of CHRYSLER GROUP, LLC
  30. Connect and lock the IAT/MAP sensor electrical connector (3).
    Fig 23: Fuel Line, Hose Retainer & Fuel Vapor Purge Hose
    GC0152408Courtesy of CHRYSLER GROUP, LLC
  31. Connect the fuel vapor purge hose (3) to the intake manifold.
  32. Connect the fuel line (2) to the fuel rail and close the hose retainer (1). Refer to FITTING, QUICK CONNECT .
    Fig 24: PCV Hose, Bolts, Vent Hose & Oil Separator Housing
    GC0152431Courtesy of CHRYSLER GROUP, LLC
  33. Install the oil separator housing (4) to the cylinder head cover with three bolts (2) tightened to 13 N.m (115 in. lbs.).
  34. Connect the vent hose (3) to the oil filler neck.
  35. Connect the PCV hose (1) to the intake manifold.
    Fig 25: Air Cleaner Body Assembly
    GC0152416Courtesy of CHRYSLER GROUP, LLC
  36. Install the air cleaner body (6). Refer to BODY, AIR CLEANER, INSTALLATION  .
    Fig 26: Engine Cover
    GC0152354Courtesy of CHRYSLER GROUP, LLC
  37. Evacuate and charge the refrigerant system. Refer to REFRIGERANT SYSTEM EVACUATE and REFRIGERANT SYSTEM CHARGE .
  38. Install the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
  39. Install the engine cover (1).
  40. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to STANDARD PROCEDURE .
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