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Home >> Fiat >> 2016 >> 500 Turbo, Standard Trans >> Repair and Diagnosis >> External Pages >> Different car >> Section 24 (1.4L 16-Valve Engine (Service Information) 500) >> Installation >> With Automatic Transmission

With Automatic Transmission

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CAUTION:

If the original engine has experienced a catastrophic failure or an individual failure with the piston, cylinder bore, engine block, valve or valve seat, the intake manifold MUST be replaced with a new manifold.

Fig 1: RH Engine Mount Bracket & Bolts
GC0152463Courtesy of CHRYSLER GROUP, LLC
NOTE:

Perform the following steps to prepare a replacement engine for installation into the vehicle.

  1. Install the RH engine mount bracket (1) with six bolts (2) tightened to 25 N.m (18 ft. lbs.).
    Fig 2: RH Engine Mount Isolator, Support Bracket & Bolts With Tightening Sequence
    GC0153367Courtesy of CHRYSLER GROUP, LLC
  2. Install the RH engine mount isolator (3) and support bracket (1) to the engine mount bracket with three bolts. Tighten the isolator to engine bracket bolts in the sequence shown in illustration to 60 N.m (44 ft. lbs.).
    Fig 3: 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.

  3. Remove the vacuum pump (1). Refer to PUMP, VACUUM, REMOVAL .
    Fig 4: Engine Lifting Bracket & Bolts
    GC0152654Courtesy of CHRYSLER GROUP, LLC
  4. Install the (special tool #10299, Bracket, Engine Lifting) (1) on the vacuum pump mounting surface with three bolts (2) provided with the engine lifting bracket. Tighten the bolts to 20 N.m (15 ft. lbs.).
    Fig 5: Engine Hoist, Engine Lifting Bracket, Engine Mounting Bracket & Load-Leveling Lifting Sling
    GC0152655Courtesy of CHRYSLER GROUP, LLC
  5. Attach a load-leveling lifting sling (4), such as OTC® 4305 Engine Load Leveler or equivalent, between the front engine mounting bracket (3), the engine lifting bracket (2) and an engine hoist (1).
    Fig 6: Accessory Mounting Bracket & Fasteners
    GC0152427Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Perform the following steps to install components on a replacement engine if required.

  6. Install the accessory mounting bracket (1) with three bolts (4) and two nuts (2 and 3) tightened as follows:
    • Three bolts (4) to 50 N.m (37 ft. lbs.)
    • One nut (3) to 50 N.m (37 ft. lbs.)
    • One nut (2) to 25 N.m (18 ft. lbs.)
  7. Install the ground wire with the bolt (5) tightened to 9 N.m (80 in. lbs.).
    Fig 7: Screw, Block Heater & Power Cord
    GC0152549Courtesy of CHRYSLER GROUP, LLC
  8. Install the block heater (3) (if equipped). Refer to HEATER, ENGINE BLOCK, INSTALLATION .
    Fig 8: Oil Level Indicator Tube & Bolt
    GC0152426Courtesy of CHRYSLER GROUP, LLC
  9. Install the oil level indicator tube (1). Tighten the bolt (2) to 9 N.m (80 in. lbs.).
    Fig 9: Discharge Line, Suction Line, A/C Compressor & Fasteners
    GC0152543Courtesy of CHRYSLER GROUP, LLC
  10. Install the A/C compressor (3) with discharge line (1) and suction line (5). Refer to COMPRESSOR, A/C, INSTALLATION .
    Fig 10: Generator & Fasteners
    GC0153159Courtesy of CHRYSLER GROUP, LLC
  11. Install the generator (3) and connect the electrical wiring. Refer to GENERATOR, INSTALLATION .
    Fig 11: Drive Belt Tensioners & Assembly With Drive Belt Routing
    GC0152365Courtesy of CHRYSLER GROUP, LLC
  12. Install the accessory drive belt (4). Refer to BELT, SERPENTINE, INSTALLATION .
    Fig 12: Transmission Adapter Plate & Fasteners
    GC0152425Courtesy of CHRYSLER GROUP, LLC
  13. Install the transmission adapter plate (1) with three bolts (3 and 4) and one bolt and nut (2) as follows:
    • One bolt (4) to 60 N.m (44 ft. lbs.)
    • One bolt and nut (2) to 60 N.m (44 ft. lbs.)
    • Two bolts (3) to 40 N.m (30 ft. lbs.)
    Fig 13: Flexplate & Bolts
    GC0152424Courtesy of CHRYSLER GROUP, LLC
  14. Install the flexplate (1). Refer to FLEXPLATE, INSTALLATION .
    Fig 14: Starter Assembly, Connector & Fasteners
    GC0153134Courtesy of CHRYSLER GROUP, LLC
  15. Install the starter assembly (5) and connect the electrical wiring (2). Refer to STARTER, INSTALLATION .
    Fig 15: Upper Transmission Mounting Bolts
    GC0152423Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Perform the following steps to install the transmission to the engine if required.

  16. Install the transmission on the engine with two upper mounting bolts (1) tightened to 60 N.m (44 ft. lbs.).
    Fig 16: Lower Transmission Mounting Bolts & Oxygen Sensor Harness Bracket
    GC0152422Courtesy of CHRYSLER GROUP, LLC
  17. Install the four lower transmission mounting bolts (1) and the oxygen sensor harness bracket (2). Tighten bolts (1) to 40 N.m (30 ft. lbs.).
    Fig 17: Torque Converter Bolts
    GC0152567Courtesy of CHRYSLER GROUP, LLC
  18. Install the six torque converter bolts (1). Tighten the six bolts in two steps as follows:
    • Step 1: All to 20 N.m (15 ft. lbs.).
    • Step 2: All to 60 N.m (44 ft. lbs.).
    Fig 18: Torque Converter Access Cover
    GC0152566Courtesy of CHRYSLER GROUP, LLC
  19. Install the torque converter access cover (1).
    Fig 19: Engine Hoist & Load-Leveling Lifting Sling
    GC0152420Courtesy of CHRYSLER GROUP, LLC
  20. Position the engine and transmission in the vehicle.
    Fig 20: LH Engine Mount Isolator & Bolts
    GC0152421Courtesy of CHRYSLER GROUP, LLC
  21. Install the LH engine mount isolator (1) with three bolts (2 and 3). First tighten the isolator to engine bracket bolt (3) to 110 N.m (81 ft. lbs.) and then tighten the isolator to body bolts (2) to 50 N.m (37 ft. lbs.).
    Fig 21: RH Engine Mount Isolator, Support Bracket & Bolts With Tightening Sequence
    GC0153367Courtesy of CHRYSLER GROUP, LLC
  22. Install the RH engine mount isolator (3) and support bracket (1) to the engine mount bracket with three bolts. Tighten the isolator to engine bracket bolts in the sequence shown in illustration to 60 N.m (44 ft. lbs.).
  23. Install the RH engine mount isolator (3) to the body with three bolts (2). Tighten the isolator to body bolts (2) to 60 N.m (44 ft. lbs.).
    Fig 22: Vacuum Pump & Connector
    GC0152398Courtesy 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.

    CAUTION:

    The vacuum hose and the pressurized coolant bottle return hose have the same quick-connect fitting end. Verify that the hoses are correctly installed. Failure to properly install the hoses can result in engine damage.

  24. Install the vacuum pump (1) and wiring harness bracket. Refer to PUMP, VACUUM, INSTALLATION .
  25. Connect the main wire harness connector (2) to the engine harness.
    Fig 23: Fuel Line, Hose Retainer & Fuel Vapor Purge Hose
    GC0152408Courtesy of CHRYSLER GROUP, LLC
  26. Connect the fuel vapor purge hose (3) to the intake manifold.
  27. Connect the fuel line (2) to the fuel rail and close the hose retainer (1). Refer to FITTING, QUICK CONNECT .
    Fig 24: A/C Suction Line, Nut, Heater Core Outlet Hose & Inlet Hose
    GC0152409Courtesy of CHRYSLER GROUP, LLC
  28. Install the A/C suction line (1) with a new O-ring seal to the A/C expansion valve. Install the nut (2) and tighten to 20 N.m (15 ft. lbs.).
  29. Connect the heater core inlet hose (4) and outlet hose (3) to the heater core.
    Fig 25: Battery Cable & Nut
    GC0152405Courtesy of CHRYSLER GROUP, LLC
  30. Install the battery cable (1) to the battery terminal and tighten the nut (2) to 5 N.m (45 in. lbs.).
    Fig 26: Gearshift Cable, Transmission Manual Valve Lever, Transmission Range Selector Switch Connector, Bracket & Bolt
    GC0152402Courtesy of CHRYSLER GROUP, LLC
  31. Install the ground strap to the transmission and tighten the bolt (3) to 9 N.m (80 in. lbs.).
  32. Install the gearshift cable (2) to the bracket (1).
  33. Connect the gearshift cable (2) to the transmission manual valve lever (4).
  34. Connect the wire harness connector (5) to the Transmission Control Module (TCM).
    Fig 27: Upper And Lower Radiator Hoses & Retainer
    GC0152419Courtesy of CHRYSLER GROUP, LLC
  35. Install the upper radiator hose (2) to the engine.
  36. Install the lower radiator hose (3) to the engine.
  37. Install the windshield washer fluid reservoir and engage the hose retainer (4) to the filler neck.
    Fig 28: Return Hose, Lower Supply Hose, Mounting Screw & Coolant Recovery Bottle
    GC0152348Courtesy of CHRYSLER GROUP, LLC
  38. Install the pressurized coolant bottle (5). Refer to BOTTLE, PRESSURIZED COOLANT, INSTALLATION .
    Fig 29: Two Bolts Of Lower Transmission Mount
    GC0152406Courtesy of CHRYSLER GROUP, LLC
  39. Raise and support the vehicle. Refer to HOISTING .
  40. Install the rear engine mount isolator (5) in the bracket (3) with two bolts (4) tighten to 60 N.m (44 ft. lbs.). Install the isolator bolt (1) and tighten to 130 N.m (96 ft. lbs.).
    Fig 30: Installing Half Shaft
    GC0152930Courtesy of CHRYSLER GROUP, LLC
  41. Install both axle shafts. Refer to REMOVAL .
    Fig 31: Upstream And Downstream Oxygen Sensors, Maniverter & Fasteners
    GC0152389Courtesy of CHRYSLER GROUP, LLC
  42. Lower the vehicle.
  43. Install the maniverter (4), cooling module, front fascia, inner wheel well splash shields, wheels and tires. Refer to MANIFOLD, EXHAUST, INSTALLATION .
    Fig 32: Lower Air Dam/Belly Pan
    GC0082359Courtesy of CHRYSLER GROUP, LLC
  44. Install the belly pan. Refer to BELLY PAN, INSTALLATION .
    Fig 33: PCM, Retainers, Ground Strap & Nuts
    GC0152394Courtesy of CHRYSLER GROUP, LLC
  45. Lower the vehicle.
  46. Position the battery tray and PCM in the vehicle. Route the wire harness and close the wire harness retainers (3).
  47. Install the ground strap (4) with nut (1) tightened to 5 N.m (44 in. lbs.).
    Fig 34: Battery Tray, Connectors, Retainers, Nut & Bolts
    GC0152563Courtesy of CHRYSLER GROUP, LLC
  48. Install the battery tray (3) with one nut (5) and two bolts (1) tightened to 25 N.m (18 ft. lbs.).
  49. Engage the engine wire harness connector (2) to the battery tray (3).
  50. Engage two engine wire harness retainers (4) to the battery tray (3).
  51. Engage two starter wire harness retainers (6) to the battery tray (3).
    Fig 35: PCM Electrical Connectors
    GC0152393Courtesy of CHRYSLER GROUP, LLC
  52. Connect the Powertrain Control Module (PCM) electrical connectors (1 and 2).
    Fig 36: PCV Hose, Bolts, Vent Hose & Oil Separator Housing
    GC0152431Courtesy of CHRYSLER GROUP, LLC
  53. Install the oil separator housing (4) to the cylinder head cover with three bolts (2) tightened to 13 N.m (115 in. lbs.).
  54. Connect the vent hose (3) to the oil filler neck.
  55. Connect the PCV hose (1) to the intake manifold.
    Fig 37: Air Cleaner Body Assembly
    GC0152416Courtesy of CHRYSLER GROUP, LLC
  56. Install the air cleaner body (6). Refer to BODY, AIR CLEANER, INSTALLATION .
    Fig 38: Engine Cover
    GC0152354Courtesy of CHRYSLER GROUP, LLC
  57. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to STANDARD PROCEDURE .
  58. Fill the cooling system. Refer to STANDARD PROCEDURE .
  59. Install and connect the battery. Refer to BATTERY, INSTALLATION .
  60. Evacuate and charge the refrigerant system. Refer to STANDARD PROCEDURE .
  61. Install the engine cover (1).
  62. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to STANDARD PROCEDURE .
  63. Check the transmission for correct fluid level. Refer to FLUID, STANDARD PROCEDURE .
    NOTE:

    The Cam/Crank Variation Relearn procedure must be performed using the scan tool anytime there has been a repair/replacement made to a powertrain system. For example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components. Refer to appropriate Engine Electrical Diagnostics article.

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