LEMON Manuals: Even more car manuals for everyone
Home >> Fiat >> 2016 >> 500 Turbo, Standard Trans >> Repair and Diagnosis >> External Pages >> Different car >> Section 24 (1.4L 16-Valve Engine (Service Information) 500) >> Removal >> With Automatic Transmission

With Automatic 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: Engine Cover
GC0152354Courtesy of CHRYSLER GROUP, LLC
NOTE:

The oil cooler can not be cleaned out. In the event that the engine requires rebuilding or replacement, replace the oil cooler. Refer to COOLER, OIL, REMOVAL .

  1. Perform the fuel pressure release procedure. Refer to FUEL SYSTEM PRESSURE RELEASE .
  2. Recover the refrigerant from the refrigerant system. Refer to STANDARD PROCEDURE .
  3. Remove the engine cover (1).
    Fig 2: Air Cleaner Body Assembly
    GC0152416Courtesy of CHRYSLER GROUP, LLC
  4. Remove the air cleaner body (6). Refer to BODY, AIR CLEANER, REMOVAL .
    Fig 3: PCV Hose, Bolts, Vent Hose & Oil Separator Housing
    GC0152431Courtesy of CHRYSLER GROUP, LLC
  5. Disconnect the PCV hose (1) from the intake manifold.
  6. Disconnect the vent hose (3) from the oil filler neck.
  7. Remove the three bolts (2) and remove the oil separator housing (4) from the cylinder head cover.
    Fig 4: 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.

  8. Disconnect and remove the battery. Refer to BATTERY, REMOVAL .
  9. Disconnect the Powertrain Control Module (PCM) harness connectors (1 and 2).
    Fig 5: Battery Tray, Connectors, Retainers, Nut & Bolts
    GC0152563Courtesy of CHRYSLER GROUP, LLC
  10. Disengage two starter wire harness retainers (6) from the battery tray (3).
  11. Disengage two engine wire harness retainers (4) from the battery tray (3).
  12. Disengage the engine wire harness connector (2) from the battery tray (3) and reposition the wire harness.
  13. Remove the nut (5) and two bolts (1).
    Fig 6: PCM, Retainers, Ground Strap & Nuts
    GC0152394Courtesy of CHRYSLER GROUP, LLC
  14. Open the two wire harness retainers (3) and reposition the wire harness.
  15. Remove the nut (1) and the ground strap (4).
  16. Remove the battery tray with the PCM (2) attached.
    Fig 7: Lower Air Dam/Belly Pan
    GC0082359Courtesy of CHRYSLER GROUP, LLC
  17. Raise and support the vehicle. Refer to HOISTING .
  18. Remove the belly pan. Refer to BELLY PAN, REMOVAL .
  19. Drain the cooling system. Refer to STANDARD PROCEDURE .
  20. Drain the engine oil. Refer to STANDARD PROCEDURE .
    Fig 8: Upstream And Downstream Oxygen Sensors, Maniverter & Fasteners
    GC0152389Courtesy of CHRYSLER GROUP, LLC
  21. Remove the maniverter (4). Refer to MANIFOLD, EXHAUST, REMOVAL .
    Fig 9: Right Side Axle Shaft
    GC0152661Courtesy of CHRYSLER GROUP, LLC
  22. Remove both axle shafts (1). Refer to REMOVALREMOVAL .
    Fig 10: Two Bolts Of Lower Transmission Mount
    GC0152406Courtesy of CHRYSLER GROUP, LLC
  23. Remove two bolts (4) from the rear engine mount bracket (3), loosen the bolt (1) and reposition the rear engine mount link (5) away from the bracket (3).
    Fig 11: Upper And Lower Radiator Hoses & Retainer
    GC0152419Courtesy of CHRYSLER GROUP, LLC
  24. Remove the upper radiator hose (2) from the engine.
  25. Disengage the hose retainer (4) and remove the windshield washer fluid reservoir. Refer to RESERVOIR, WINDSHIELD WASHER, REMOVAL .
  26. Remove the lower radiator hose (3) from the engine.
    Fig 12: Return Hose, Lower Supply Hose, Mounting Screw & Coolant Recovery Bottle
    GC0152348Courtesy of CHRYSLER GROUP, LLC
  27. Remove the pressurized coolant bottle (5). Refer to BOTTLE, PRESSURIZED COOLANT, REMOVAL .
    Fig 13: Gearshift Cable, Transmission Manual Valve Lever, Transmission Range Selector Switch Connector, Bracket & Bolt
    GC0152402Courtesy of CHRYSLER GROUP, LLC
  28. Disconnect the wire harness connector (5) from the Transmission Control Module (TCM).
  29. Disconnect the gearshift cable (2) from the transmission manual valve lever (4).
  30. Remove the gearshift cable (2) from the bracket (1).
  31. Remove the bolt (3) and the ground strap from the transmission.
    Fig 14: Battery Cable & Nut
    GC0152405Courtesy of CHRYSLER GROUP, LLC
  32. Remove the nut (2) and the battery cable (1) from the battery terminal.
    Fig 15: A/C Suction Line, Nut, Heater Core Outlet Hose & Inlet Hose
    GC0152409Courtesy of CHRYSLER GROUP, LLC
  33. Disconnect the heater core outlet hose (3) and inlet hose (4) from the heater core.
  34. Remove the nut (2) and disconnect the A/C suction line (1) from the A/C expansion valve. Install plugs in, or tape over all the opened refrigerant line fittings and expansion valve ports.
    Fig 16: Fuel Line, Hose Retainer & Fuel Vapor Purge Hose
    GC0152408Courtesy of CHRYSLER GROUP, LLC
  35. Disconnect the fuel vapor purge hose (3) from the intake manifold.
  36. Open the hose retainer (1). Disconnect the fuel line (2) from the fuel rail. Refer to FITTING, QUICK CONNECT .
    Fig 17: Vacuum Pump & Connector
    GC0152398Courtesy of CHRYSLER GROUP, LLC
  37. Disconnect the main wire harness connector (2) from the engine harness.
    CAUTION:

    The vacuum hose and the afterrun coolant pump hose have the same quick-connect fitting end. If removing both hoses, it is recommended that the hoses be marked at disassembly to avoid an incorrect installation. Failure to properly install the hoses can result in engine damage.

  38. Remove the vacuum pump (1). Refer to PUMP, VACUUM, REMOVAL .
    Fig 18: Engine Lifting Bracket & Bolts
    GC0152654Courtesy of CHRYSLER GROUP, LLC
  39. 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 19: Engine Hoist & Load-Leveling Lifting Sling
    GC0152420Courtesy of CHRYSLER GROUP, LLC
  40. Reposition the main wire harness over the left frame extension.
  41. Attach a load-leveling lifting sling (2), such as OTC® 4305 Engine Load Leveler or equivalent, between the front engine mounting bracket, the engine lifting bracket and an engine hoist (1).
    Fig 20: LH Engine Mount Isolator & Bolts
    GC0152421Courtesy of CHRYSLER GROUP, LLC
  42. Remove the three bolts (2 and 3) and the LH engine mount isolator (1).
    Fig 21: Three Right Side Engine Mount Support Bolts
    GC0152565Courtesy of CHRYSLER GROUP, LLC
  43. Remove the three bolts (3) from the RH engine mount isolator (1).
  44. Remove the engine and transmission from the vehicle.
    Fig 22: Torque Converter Access Cover
    GC0152566Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Perform the following steps to remove the transmission from the engine if required.

  45. Remove the torque converter access cover (1).
    Fig 23: Torque Converter Bolts
    GC0152567Courtesy of CHRYSLER GROUP, LLC
  46. Remove the six torque converter bolts (1).
    Fig 24: Lower Transmission Mounting Bolts & Oxygen Sensor Harness Bracket
    GC0152422Courtesy of CHRYSLER GROUP, LLC
  47. Remove the four lower transmission mounting bolts (1) and the oxygen sensor harness bracket (2).
    Fig 25: Upper Transmission Mounting Bolts
    GC0152423Courtesy of CHRYSLER GROUP, LLC
  48. Position a transmission jack under the transmission. Secure the transmission to the transmission jack.
  49. Remove the two upper transmission mounting bolts (1) and separate the transmission from the engine.
    Fig 26: Starter Assembly, Connector & Fasteners
    GC0153134Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Perform the following steps to remove components for installation on a replacement engine if required.

  50. Remove the starter assembly (5). Refer to STARTER, REMOVAL .
    Fig 27: Flexplate & Bolts
    GC0152424Courtesy of CHRYSLER GROUP, LLC
  51. Remove the flexplate (1). Refer to FLEXPLATE, REMOVAL .
    Fig 28: Transmission Adapter Plate & Fasteners
    GC0152425Courtesy of CHRYSLER GROUP, LLC
  52. Remove three bolts (3 and 4), one bolt and nut (2) and the transmission adapter plate (1).
    Fig 29: Drive Belt Tensioners & Assembly With Drive Belt Routing
    GC0152365Courtesy of CHRYSLER GROUP, LLC
  53. Remove the accessory drive belt (4). Refer to BELT, SERPENTINE, REMOVAL .
    Fig 30: Generator & Fasteners
    GC0153159Courtesy of CHRYSLER GROUP, LLC
  54. Remove the generator (3). Refer to GENERATOR, REMOVAL .
    Fig 31: A/C Compressor Assembly
    GC0152542Courtesy of CHRYSLER GROUP, LLC
  55. Remove the A/C compressor (1). Refer to COMPRESSOR, A/C, REMOVAL .
    Fig 32: Oil Level Indicator Tube & Bolt
    GC0152426Courtesy of CHRYSLER GROUP, LLC
  56. Remove the bolt (2) and the oil level indicator tube (1).
    Fig 33: Accessory Mounting Bracket & Fasteners
    GC0152427Courtesy of CHRYSLER GROUP, LLC
  57. Remove the bolt (5) and the ground wire.
  58. Remove three bolts (3), two nuts (2 and 3) and the accessory mounting bracket (1).
    Fig 34: Screw, Block Heater & Power Cord
    GC0152549Courtesy of CHRYSLER GROUP, LLC
  59. Remove the block heater (3) (if equipped). Refer to HEATER, ENGINE BLOCK, REMOVAL .
    Fig 35: RH Engine Mount Bracket & Bolts
    GC0152463Courtesy of CHRYSLER GROUP, LLC
  60. Install the engine on an engine stand such as OTC® 1726A 1, 000 LB. Capacity Engine Stand or equivalent, and remove the lifting sling.
  61. Remove six bolts (2) and the RH engine mount bracket (1).
scientia non olet · About LEMON Manuals