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Home >> Fiat >> 2016 >> 500 Pop, Standard Trans >> Repair and Diagnosis >> External Pages >> Different car >> Section 25 (1.4L 16-Valve Turbo Engine (Service Information) 500) >> Cylinder Head >> Cover(S), Cylinder Head >> Removal >> Removal

Cover(S), Cylinder Head: Removal: Removal

WARNING: This page is about a different car, the 2015 Fiat 500. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Air Cleaner Assembly, Intake Hose, Fittings & Clamp
GC0153787Courtesy of CHRYSLER GROUP, LLC
  1. Perform the fuel pressure release procedure.

    Refer to FUEL SYSTEM PRESSURE RELEASE .

  2. Disconnect and isolate the negative battery cable.
  3. Remove the air cleaner body (1).

    Refer to BODY, AIR CLEANER, REMOVAL .

    Fig 2: Turbocharger Support Bracket & Fasteners
    GC0157577Courtesy of CHRYSLER GROUP, LLC
  4. Remove two bolts (1), one nut (3), and the turbocharger support bracket (2).
    Fig 3: PCV Hose, Vent Hose, Oil Separator Housing & Bolts
    GC0155887Courtesy of CHRYSLER GROUP, LLC
  5. Disconnect the PCV hose (1) from the intake manifold.
  6. Disconnect the vent hose (3) from the cylinder head cover.
  7. Remove three bolts (2) and remove the oil separator housing (4) from the cylinder head cover.
    Fig 4: Fuel Purge Hose & Hose Retainer
    GC0156457Courtesy of CHRYSLER GROUP, LLC
  8. Open the hose retainer (3) and disconnect the fuel vapor purge hose (2).
  9. Disconnect the fuel line (1) from the fuel rail.

    Refer to FITTING, QUICK CONNECT .

    Fig 5: Purge Flow Control Solenoid & Bracket
    GC0156078Courtesy of CHRYSLER GROUP, LLC
  10. Disengage and reposition the purge flow control solenoid (1) from the bracket (4).
    Fig 6: Vacuum Pump & Bolts
    GC0152461Courtesy 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.

  11. Disconnect the vacuum line from the vacuum pump (1).
    Fig 7: Support Brackets, Bolts, Retainers & Nuts
    GC0155583Courtesy of CHRYSLER GROUP, LLC
  12. Remove the nuts (1), bolt (7) and bracket (2).
  13. Disengage the retainer (5) from the support bracket (4).
  14. Remove the nut (3), bolt (6) and support bracket (4).
    Fig 8: Oil Separator Housing Bracket & Fasteners
    GC0152568Courtesy of CHRYSLER GROUP, LLC
  15. Remove two bolts (2), one nut (3) and reposition the oil separator housing bracket (1).
    Fig 9: Ignition Coil, Connector & Bolt
    GC0157782Courtesy of CHRYSLER GROUP, LLC
    NOTE:

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

  16. Remove the ignition coils (3).

    Refer to COIL, IGNITION, REMOVAL .

    Fig 10: Wire Harness Duct & Bolts
    GC0152433Courtesy of CHRYSLER GROUP, LLC
  17. Remove the bolt (2) and the ground lug from the cylinder head cover.
  18. Remove two bolts (3) and reposition the wire harness duct (1).
    Fig 11: Wastegate Actuator Hose, Solenoid, Electrical Connector, Vacuum Supply Hose & Nut
    GC0156333Courtesy of CHRYSLER GROUP, LLC
  19. Remove the bolt (5) and reposition the turbocharger wastegate solenoid (4).
    Fig 12: Upper Timing Belt Cover, Evaporative Emissions Purge Hose, Coolant Pump Return Hose & Wastegate Solenoid Pressure Inlet Hose
    GC0155975Courtesy of CHRYSLER GROUP, LLC
  20. Disengage the following retainers from the upper timing belt cover (1) :
    • EVAP purge hose (4).
    • After-run coolant pump return hose (3).
    • Wastegate solenoid pressure inlet hose (2).
    Fig 13: Upper Timing Belt Cover & Bolts
    GC0152466Courtesy of CHRYSLER GROUP, LLC
  21. Remove the bolts (2 and 3) and the upper timing belt cover (1).
    Fig 14: Cylinder Head Cover & Bolts
    GC0157897Courtesy of CHRYSLER GROUP, LLC
  22. Remove twelve bolts (2) and the cylinder head cover (1).
    Fig 15: Cylinder Head Cover Gasket & Spark Plug Tube Seals
    GC0152496Courtesy of CHRYSLER GROUP, LLC
  23. Remove and discard the cylinder head cover gasket (1).
  24. The spark plug tube seals (2) can be reused if not damaged.
    Fig 16: Residual Sealant Locations
    GC0152475Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    Do not use oil based liquids, wire brushes, abrasive wheels or metal scrapers to clean the engine gasket surfaces. Use only isopropyl (rubbing) alcohol, along with plastic or wooden scrapers. Improper gasket surface preparation may result in engine fluid leakage.

  25. Remove all residual sealant (1) from the variable valve actuator assembly, camshaft caps, camshaft housing and cylinder head cover mating surfaces.

    Refer to ENGINE GASKET SURFACE PREPARATION .

    Fig 17: Oil Filler Neck, Oil Filler Neck Lock & Bolt
    GC0152569Courtesy of CHRYSLER GROUP, LLC
  26. If required, remove the bolt (3), oil filler neck lock (2) and the oil filler neck (1) from the cylinder head cover.
    Fig 18: Oil Filler Neck O-Ring
    GC0157574Courtesy of CHRYSLER GROUP, LLC
  27. The oil filler neck O-ring (1) can be reused if not damaged.
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