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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 Manual Transmission

With Manual Transmission

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.
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. NOTE:

    Automatic transmission equipped engine mount shown in illustration, manual transmission equipped engine mount similar.

    Fig 3: Vacuum Pump & Bolts
    GC0152461Courtesy 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.).
    3. 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 4: Engine Lifting Bracket & Bolts
    GC0152654Courtesy of CHRYSLER GROUP, LLC
  3. Remove the vacuum pump (1). Refer to PUMP, VACUUM, REMOVAL .
  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
    6. 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: Flywheel Dust Cover & Bolt
    GC0153316Courtesy of CHRYSLER GROUP, LLC
  13. Install the flywheel dust cover (2). Tighten the bolt (1) to 9 N.m (80 in. lbs.).
    Fig 13: Flywheel-To-Crankshaft Bolts
    GC0152723Courtesy of CHRYSLER GROUP, LLC
  14. Install the flywheel. Refer to FLYWHEEL, INSTALLATION .
    Fig 14: Pressure Plate Bolts
    GC0152711Courtesy of CHRYSLER GROUP, LLC
  15. Install the clutch pressure plate and disc. Refer to DISC, CLUTCH, INSTALLATION .
    Fig 15: Upper Bell Housing Bolts
    GC0152751Courtesy of CHRYSLER GROUP, LLC
    16. NOTE:

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

    Fig 16: Transmission Bell Housing Bolts, Nut & Stud
    GC0152757Courtesy of CHRYSLER GROUP, LLC
  16. Install the transmission on the engine with the upper bell housing bolts (1) tightened to 60 N.m (44 ft. lbs.).
  17. Install the nut (1) and stud (2) and tighten to 60 N.m (44 ft. lbs.).
  18. Install the remaining transmission bell housing bolts (3) and tighten to 40 N.m (30 ft. lbs.).
    Fig 17: Flywheel Dust Cover Bolts
    GC0153313Courtesy of CHRYSLER GROUP, LLC
  19. Install the two bolts (1) to the flywheel dust cover and tighten to 9 N.m (80 in. lbs.).
    Fig 18: Starter Assembly, Connector & Fasteners
    GC0153134Courtesy of CHRYSLER GROUP, LLC
  20. Install the starter assembly (5) and connect the electrical wiring (2). Refer to STARTER, INSTALLATION .
    Fig 19: Engine Hoist & Load-Leveling Lifting Sling
    GC0152420Courtesy of CHRYSLER GROUP, LLC
  21. Position the engine and transmission in the vehicle.
    Fig 20: LH Engine Mount Isolator & Bolts
    GC0152421Courtesy of CHRYSLER GROUP, LLC
    22. NOTE:

    Automatic transmission equipped engine mount shown in illustration, manual transmission equipped engine mount similar.

    Fig 21: RH Engine Mount Isolator, Support Bracket & Bolts With Tightening Sequence
    GC0153367Courtesy of CHRYSLER GROUP, LLC
  22. 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.).
    23. NOTE:

    Automatic transmission equipped engine mount shown in illustration, manual transmission equipped engine mount similar.

  23. 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.).
  24. 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
    25. 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.

  25. Install the vacuum pump (1) and wiring harness bracket. Refer to PUMP, VACUUM, INSTALLATION .
  26. 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
  27. Connect the fuel vapor purge hose (3) to the intake manifold.
  28. 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
  29. 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.).
  30. 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
  31. Install the battery cable (1) to the battery terminal and tighten the nut (2) to 5 N.m (45 in. lbs.).
    Fig 26: Shift Cable
    GC0152839Courtesy of CHRYSLER GROUP, LLC
  32. Connect the shift cable (1) to the lever.
    Fig 27: Cable Mounting Bracket
    GC0152841Courtesy of CHRYSLER GROUP, LLC
  33. Install the retainer (1) to the shift cable.
    Fig 28: Shift Selector Cable
    GC0152746Courtesy of CHRYSLER GROUP, LLC
  34. Connect the shift selector cable (1) to the lever.
    Fig 29: Cable Retention Clip
    GC0152840Courtesy of CHRYSLER GROUP, LLC
  35. Install the retainer (1) to the shift selector cable.
    Fig 30: Ground Strap
    GC0152744Courtesy of CHRYSLER GROUP, LLC
  36. Install the ground strap (1) to the transmission.
    Fig 31: Reverse Lamp Switch Connector
    GC0152745Courtesy of CHRYSLER GROUP, LLC
  37. Connect the electrical connector (1) to the reverse lamp switch.
    Fig 32: Slave Cylinder Bolts
    GC0152820Courtesy of CHRYSLER GROUP, LLC
  38. Install the hydraulic clutch slave cylinder to the transmission with two bolts (1). Tighten the bolts to 20 N.m (15 ft. lbs.).
    Fig 33: Hydraulic Clutch Line Support Bracket & Bolts
    GC0153302Courtesy of CHRYSLER GROUP, LLC
  39. Install the hydraulic clutch line support bracket (2) to the transmission with two bolts (1).
    Fig 34: Upper And Lower Radiator Hoses & Retainer
    GC0152419Courtesy of CHRYSLER GROUP, LLC
  40. Install the upper radiator hose (2) to the engine.
  41. Install the lower radiator hose (3) to the engine.
  42. Install the windshield washer fluid reservoir and engage the hose retainer (4) to the filler neck.
    Fig 35: Return Hose, Lower Supply Hose, Mounting Screw & Coolant Recovery Bottle
    GC0152348Courtesy of CHRYSLER GROUP, LLC
  43. Install the pressurized coolant bottle (5) Refer to BOTTLE, PRESSURIZED COOLANT, INSTALLATION .
    Fig 36: Rear Engine Mount Bracket, Isolator & Fasteners
    GC0153301Courtesy of CHRYSLER GROUP, LLC
  44. Raise and support the vehicle. Refer to HOISTING .
  45. Install the rear engine mount bracket (5) with two bolts (2 and 4).
  46. Install the rear engine mount isolator (7) to the transmission with the rear engine mount bracket bolt (3) and nut (6) tightened to 80 N.m (59 ft. lbs.).
  47. Tighten the isolator bolt (1) to 130 N.m (96 ft. lbs.).
    Fig 37: Installing Half Shaft
    GC0152930Courtesy of CHRYSLER GROUP, LLC
  48. Install both axle shafts. Refer to INSTALLATION .
  49. Fill the transmission with the proper fluid to the correct level. Refer to FLUID .
  50. Lower the vehicle.
  51. Clean the mating surfaces of the cylinder head and the maniverter flange.
  52. Install a new maniverter gasket on the cylinder head.
    Fig 38: Upstream And Downstream Oxygen Sensors, Maniverter & Fasteners
    GC0152389Courtesy of CHRYSLER GROUP, LLC
    53. CAUTION:

    The maniverter studs are installed in the cylinder head with a thread sealant. If the studs rotate during service this indicates that the seal is broken and the stud must be replaced. Failure to replace the studs can result in engine oil leaking onto the exhaust manifold.

  53. Mark the end of the nine maniverter mounting studs with a paint pen or equivalent to indicate possible stud rotation.
  54. Guide the maniverter (4) into place onto the studs. Install and tighten the nine nuts (1) to 20 N.m (15 ft. lbs.).
  55. Check the markings on the studs for indication of rotation. If there is evidence of stud rotation, replace the stud. Refer to MANIFOLD, EXHAUST, STANDARD PROCEDURE .
  56. Connect the upstream (2) and downstream (3) oxygen sensor electrical connectors.
    Fig 39: Maniverter Heat Shield & Fasteners
    GC0152388Courtesy of CHRYSLER GROUP, LLC
  57. Install the maniverter heat shield (2) with four bolts (3) and two nuts (1). Tighten the nuts (1) and bolts (3) to 9 N.m (80 in. lbs.).
    Fig 40: Front Exhaust Pipe Support Bolt & Flange Nuts
    GC0153120Courtesy of CHRYSLER GROUP, LLC
  58. Raise and support the vehicle. Refer to HOISTING .
  59. Install the muffler flexible intake pipe to the maniverter flange with two nuts (1). Tighten the nuts (1) to 25 N.m (18 ft. lbs.).
  60. Install the maniverter pipe extension support to the oil pan. Tighten the bolt (2) to 50 N.m (37 ft. lbs.).
    Fig 41: Front Cooling Module Assembly & Fasteners
    GC0153119Courtesy of CHRYSLER GROUP, LLC
  61. Install the front cooling module assembly (4) with four bolts (1), eight bolts and washers (2) and eight bolts and washers (3). Tighten the eight bolts (2) to 45 N.m (33 ft. lb.). Tighten the four bolts (1) to 24 N.m (18 ft. lb.). Tighten the eight bolts (3) to 45 N.m (33 ft. lb.).
    Fig 42: View Of Wire Harness
    GC0103128Courtesy of CHRYSLER GROUP, LLC
  62. Engage the wire harness retainer (1) to the bottom of the bumper reinforcement.
    Fig 43: Wire Harness Push Pin
    GC0103127Courtesy of CHRYSLER GROUP, LLC
  63. Engage the wire harness connector (1) to the bumper reinforcement.
    Fig 44: Horn, Connector & Fasteners
    GC0084012Courtesy of CHRYSLER GROUP, LLC
  64. Connect the electrical connector (2) to the horn (1).
    Fig 45: Removing/Installing Front Impact Sensor
    GC0084280Courtesy of CHRYSLER GROUP, LLC
  65. Connect the electrical connector (1) to the right and left front impact sensors (3). Refer to SENSOR, IMPACT, INSTALLATION .
    Fig 46: Latch Cable
    GC0084616Courtesy of CHRYSLER GROUP, LLC
  66. Press down the latch release (3) and install the hood latch cable (2) to the latch.
    Fig 47: A/C Liquid Line, A/C Discharge Line, A/C Condenser Tapping Block & Bolt
    GC0152540Courtesy of CHRYSLER GROUP, LLC
  67. Engage the A/C liquid line (1) to the A/C discharge line (2) and connect the lines to the A/C condenser tapping block (3) using new dual plain seals lubricated with clean refrigerant oil. Install the retaining bolt (4) and tighten to 14 N.m (10 ft. lbs.).
    Fig 48: Engine Cooling Fan, Connector & Fasteners
    GC0152367Courtesy of CHRYSLER GROUP, LLC
  68. Connect the lower coolant hose to the radiator.
  69. Connect the cooling fan electrical connector (3).
    Fig 49: Cooling Fan Resistor & Fan Assembly
    GC0152401Courtesy of CHRYSLER GROUP, LLC
  70. Connect the upper coolant hose to the radiator.
  71. Connect the electrical connector to the cooling fan resistor (1).
    Fig 50: Left Headlamp & Fasteners
    GC0153009Courtesy of CHRYSLER GROUP, LLC
  72. Install the right and left headlamp units (2) Refer to UNIT, HEADLAMP, INSTALLATION .
    Fig 51: Front Fascia
    GC0153127Courtesy of CHRYSLER GROUP, LLC
  73. Install the front fascia (1). Refer to FASCIA, FRONT, INSTALLATION .
  74. Install both front inner wheel well splash shields. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE, INSTALLATION .
  75. Install both front tire and wheel assemblies. Refer to INSTALLATION .
    Fig 52: Tunnel Support Brace & Bolts
    GC0152449Courtesy of CHRYSLER GROUP, LLC
  76. Remove the four bolts (1) and install the tunnel support brace (2). Reinstall the four bolts (1) and tighten to 90 N.m (60 ft. lb.).
    Fig 53: Lower Air Dam/Belly Pan
    GC0082359Courtesy of CHRYSLER GROUP, LLC
  77. Install the belly pan. Refer to BELLY PAN, INSTALLATION .
    Fig 54: PCM, Retainers, Ground Strap & Nuts
    GC0152394Courtesy of CHRYSLER GROUP, LLC
  78. Lower the vehicle.
  79. Position the battery tray and PCM in the vehicle. Route the wire harness and close the wire harness retainers (3).
  80. Install the ground strap (4) with nut (1) tightened to 5 N.m (44 in. lbs.).
    Fig 55: Battery Tray, Connectors, Retainers, Nut & Bolts
    GC0152563Courtesy of CHRYSLER GROUP, LLC
  81. Install the battery tray (3) with one nut (5) and two bolts (1) tightened to 25 N.m (18 ft. lbs.).
  82. Engage the engine wire harness connector (2) to the battery tray (3).
  83. Engage two engine wire harness retainers (4) to the battery tray (3).
  84. Engage two starter wire harness retainers (6) to the battery tray (3).
    Fig 56: PCM Electrical Connectors
    GC0152393Courtesy of CHRYSLER GROUP, LLC
  85. Connect the Powertrain Control Module (PCM) harness connectors (1 and 2).
    Fig 57: PCV Hose, Bolts, Vent Hose & Oil Separator Housing
    GC0152431Courtesy of CHRYSLER GROUP, LLC
  86. Install the oil separator housing (4) to the cylinder head cover with three bolts (2) tightened to 13 N.m (115 in. lbs.).
  87. Connect the vent hose (3) to the oil filler neck.
  88. Connect the PCV hose (1) to the intake manifold.
    Fig 58: Air Cleaner Body Assembly
    GC0152416Courtesy of CHRYSLER GROUP, LLC
  89. Install the air cleaner body (6). Refer to BODY, AIR CLEANER, INSTALLATION .
    Fig 59: Engine Cover
    GC0152354Courtesy of CHRYSLER GROUP, LLC
  90. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to STANDARD PROCEDURE .
  91. Fill the transmission. Refer to FLUID .
  92. Fill the cooling system. Refer to STANDARD PROCEDURE .
  93. Install and connect the battery. Refer to BATTERY, INSTALLATION .
  94. Evacuate and charge the refrigerant system. Refer to STANDARD PROCEDURE .
  95. Install the engine cover (1).
  96. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to 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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