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Home >> Fiat >> 2016 >> 500 Turbo, Automatic Trans >> Repair and Diagnosis >> Engine Mechanical >> Blowers, Superchargers & Turbochargers >> 1.4L 16-Valve Turbo Engine (Service Information) 500 >> Manifolds >> Manifold, Intake >> Installation >> Installation

Manifold, Intake: Installation: Installation

Fig 1: Intake Manifold Seals
GC0156373Courtesy of CHRYSLER GROUP, LLC
  1. If required, install the following components on the intake manifold:
  2. Install four new intake manifold seals (1).
    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.

    Fig 2: Intake Manifold Flange Bolts
    GC0152435Courtesy of CHRYSLER GROUP, LLC
  3. Install the intake manifold (1) to the engine through the space normally occupied by the battery. Loosely install an intake manifold flange bolt and the support bolt to hold the intake manifold in position.
  4. Install the remaining six of the seven intake manifold flange bolts. Tighten all seven intake manifold flange bolts to 15 N.m (11 ft. lbs.).
    Fig 3: Hose Retainer & Bolt
    GC0156303Courtesy of CHRYSLER GROUP, LLC
  5. Install the bolt (2) securing the hose retainer (1) to the intake manifold and securely tighten.
    Fig 4: Wire Harness Retainers
    GC0152434Courtesy of CHRYSLER GROUP, LLC
  6. Raise and support the vehicle.

    Refer to HOISTING .

  7. Position the wire harness into the two wire harness retainers (1) and close retainers.
  8. Lower the vehicle.
    Fig 5: A/C Suction Line, Nut, Heater Core Outlet Hose & Inlet Hose
    GC0152409Courtesy of CHRYSLER GROUP, LLC
  9. Connect the heater core outlet hose (3) and inlet hose (4) to the heater core.
    Fig 6: A/C Compressor & Fasteners
    GC0152459Courtesy of CHRYSLER GROUP, LLC
  10. Install the A/C compressor (1).

    Refer to COMPRESSOR, A/C, INSTALLATION .

    Fig 7: Drive Belt Tensioners & Assembly With Drive Belt Routing
    GC0152365Courtesy of CHRYSLER GROUP, LLC
  11. Raise and support the vehicle.

    Refer to HOISTING .

  12. Install the accessory drive belt (4).

    Refer to BELT, SERPENTINE, INSTALLATION .

    Fig 8: Right Vertical Brace, Frame Splash Shield & Fasteners
    GC0153366Courtesy of CHRYSLER GROUP, LLC
  13. Install the frame splash shield (3) with three screws (1).
  14. Install two screws (2) to the front wheelhouse splash shield.
  15. Install the right vertical brace (5) with two bolts (4) tightened to 45 N.m (33 ft. lbs.).
    Fig 9: Tunnel Support Brace & Bolts
    GC0152449Courtesy of CHRYSLER GROUP, LLC
  16. Install both front wheels and tires.

    Refer to INSTALLATION .

  17. Install the tunnel support brace (2). Tighten bolts (1) to 100 N.m (74 ft. lbs.).
    Fig 10: Lower Air Dam/Belly Pan
    GC0082359Courtesy of CHRYSLER GROUP, LLC
  18. Install the belly pan.

    Refer to BELLY PAN, INSTALLATION .

  19. Lower the vehicle.
    Fig 11: Support Brackets, Bolts, Retainers & Nuts
    GC0155583Courtesy of CHRYSLER GROUP, LLC
  20. Install the support bracket (4), nut (3), bolt (6), and tighten to 9 N.m (80 in. lbs.).
  21. Engage the retainers (5) to the support bracket (4).
  22. Install the bracket (2), two nuts (1), bolt (7), and tighten to N.m (80 in. lbs.).
  23. Connect the vacuum supply line to the pump (1).
    Fig 12: Purge Flow Control Solenoid & Bracket
    GC0156078Courtesy of CHRYSLER GROUP, LLC
  24. Reposition and engage the purge flow control solenoid (1) to the bracket (4).
    Fig 13: Fuel Injector Wire Harness Connector
    GC0156042Courtesy of CHRYSLER GROUP, LLC
  25. Connect and lock and the fuel injector wire harness connector (1).
    Fig 14: IAT/MAP Sensor Harness Connector
    GC0155684Courtesy of CHRYSLER GROUP, LLC
  26. Connect and lock the IAT/MAP sensor harness connector (1).
    Fig 15: 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.

  27. Connect the vacuum line to the vacuum pump (1).
    Fig 16: Fuel Purge Hose & Hose Retainer
    GC0156457Courtesy of CHRYSLER GROUP, LLC
  28. Connect the fuel vapor purge hose and close the hose retainer (2).
  29. Connect the fuel line (1) to the fuel rail.

    Refer to FITTING, QUICK CONNECT .

    Fig 17: EVAP Purge Hose, Charge Air Cooler Outlet Hose, Retaining Clip, Bolt & Wire Harness Connector
    GC0155526Courtesy of CHRYSLER GROUP, LLC
  30. Install the hose and connect the charge air cooler outlet hose (5) to the charge air outlet manifold.
  31. Install the bolts (3) to the charge air cooler outlet hose (5) and securely tighten
  32. Connect the boost pressure sensor wire harness connector (1).
  33. Install the hose to the charge air cooler outlet hose (5) and engage the EVAP purge hose (4) to the retaining clip (2).
    Fig 18: Oil Separator Housing Bracket & Fasteners
    GC0152568Courtesy of CHRYSLER GROUP, LLC
  34. 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: EVAP Purge Hose, ETC Harness Connector, Retaining Clip & Clamp
    GC0156027Courtesy of CHRYSLER GROUP, LLC
  35. Tighten the clamp (2) securing the charge air cooler outlet hose to throttle body.
  36. Connect the EVAP purge hose (4) to the retaining clip (3).
  37. Connect and lock the wire harness connector (3) to the Electronic Throttle Control (ETC).
    Fig 20: Battery Tray, Connectors, Retainers, Nut & Bolts
    GC0152563Courtesy of CHRYSLER GROUP, LLC
  38. Position the battery tray (3) and PCM in the vehicle.
  39. Install the battery tray nut (5) and two bolts (1). Tighten all three fasteners to 25 N.m (18 ft. lbs.).
  40. Engage the engine wire harness connector (2) to the battery tray (3).
  41. Engage two engine wire harness retainers (4) to the battery tray (3).
    Fig 21: PCM Electrical Connectors
    GC0152393Courtesy 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.

  42. Connect the Powertrain Control Module (PCM) harness connectors (1 and 2).
  43. Install the oil separator housing to the cylinder head cover with three bolts tightened to 13 N.m (115 in. lbs.).
  44. Connect the vent hose to the cylinder head cover.
  45. Connect the PCV hose to the intake manifold.
  46. Install the engine cover assembly.
  47. Evacuate and charge the refrigerant system.

    Refer to STANDARD PROCEDURE .

  48. Fill the cooling system.

    Refer to STANDARD PROCEDURE .

  49. Install and connect the battery.

    Refer to BATTERY, INSTALLATION .

  50. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level.

    Refer to STANDARD PROCEDURE .

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