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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) >> Removal >> 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: 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.
    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: PCM Electrical Connectors
    GC0152393Courtesy of CHRYSLER GROUP, LLC
  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 transmission fluid. Refer to FLUID .
  21. Drain the engine oil. Refer to STANDARD PROCEDURE .
    Fig 8: Tunnel Support Brace & Bolts
    GC0152449Courtesy of CHRYSLER GROUP, LLC
  22. Remove the four bolts (1) and the tunnel support brace (2). Reinstall the four bolts (1) to maintain alignment of the frame extensions. Tighten the bolts (1) to 90 N.m (60 ft. lb.).
  23. Remove both front tire and wheel assemblies. Refer to REMOVAL .
  24. Remove both front inner wheel well splash shields. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE, REMOVAL .
  25. Remove the front fascia (1). Refer to FASCIA, FRONT, REMOVAL .
  26. Remove the right and left headlamp units.
    Fig 9: Cooling Fan Resistor & Fan Assembly
    GC0152401Courtesy of CHRYSLER GROUP, LLC
  27. Disconnect the upper coolant hose from the radiator.
  28. Disconnect the electrical connector from the cooling fan resistor (1).
    Fig 10: Engine Cooling Fan, Connector & Fasteners
    GC0152367Courtesy of CHRYSLER GROUP, LLC
  29. Disconnect the lower coolant hose from the radiator.
  30. Disconnect the cooling fan electrical connector (3).
    Fig 11: A/C Liquid Line, A/C Discharge Line, A/C Condenser Tapping Block & Bolt
    GC0152540Courtesy of CHRYSLER GROUP, LLC
  31. Remove the bolt (4) and disconnect the A/C liquid line (1) and the A/C discharge line (2) from the A/C condenser tapping block (3).
  32. Separate the A/C liquid line from the A/C discharge line. Remove and discard the dual plain seals.
  33. Install plugs in, or tape over, the opened refrigerant line fittings and condenser ports.
    Fig 12: Latch Cable
    GC0084616Courtesy of CHRYSLER GROUP, LLC
  34. Press down the latch release (3) and remove the hood latch cable (2) from the latch.
    Fig 13: Removing/Installing Front Impact Sensor
    GC0084280Courtesy of CHRYSLER GROUP, LLC
  35. Disconnect the wire harness connector (1) from the right and left front impact sensors (3). Refer to SENSOR, IMPACT, REMOVAL .
    Fig 14: Horn, Connector & Fasteners
    GC0084012Courtesy of CHRYSLER GROUP, LLC
  36. Disconnect the wire harness connector (2) from the horn (1).
    Fig 15: Wire Harness Push Pin
    GC0103127Courtesy of CHRYSLER GROUP, LLC
  37. Disengage the wire harness connector (1) from the bumper reinforcement.
    Fig 16: View Of Wire Harness
    GC0103128Courtesy of CHRYSLER GROUP, LLC
  38. Disengage the wire harness retainer (1) from the bottom of the bumper reinforcement.
    Fig 17: Front Cooling Module Assembly & Fasteners
    GC0153119Courtesy of CHRYSLER GROUP, LLC
  39. Remove the four bolts (1), eight bolts and washers (2), eight bolts and washers (3) and the cooling module assembly (4) from the vehicle.
    Fig 18: Front Exhaust Pipe Support Bolt & Flange Nuts
    GC0153120Courtesy of CHRYSLER GROUP, LLC
  40. Remove the exhaust flange nuts (1).
  41. Remove the maniverter pipe extension support bolt (2).
    Fig 19: Maniverter Heat Shield & Fasteners
    GC0152388Courtesy of CHRYSLER GROUP, LLC
  42. Remove the two nuts (1), four bolts (3) and the maniverter heat shield (2).
    Fig 20: Upstream And Downstream Oxygen Sensors, Maniverter & Fasteners
    GC0152389Courtesy of CHRYSLER GROUP, LLC
  43. Disconnect the electrical connectors from the upstream (2) and downstream (3) oxygen sensors.
    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.

  44. Mark the end of the nine maniverter mounting studs with a paint pen or equivalent to indicate possible stud rotation.
  45. Remove nine nuts (1) and remove the maniverter (4) from the cylinder head.
  46. 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 .
  47. Remove and discard the maniverter gasket.
    Fig 21: Right Side Axle Shaft
    GC0152661Courtesy of CHRYSLER GROUP, LLC
  48. Remove both axle shafts (1). Refer to REMOVAL .
    Fig 22: Rear Engine Mount Bracket, Isolator & Fasteners
    GC0153301Courtesy of CHRYSLER GROUP, LLC
  49. Remove the rear engine mount bracket bolt (3) and nut (6).
  50. Remove the two bolts (2 and 4) and remove the rear engine mount bracket (5).
  51. Loosen the isolator bolt (1) and reposition the rear engine mount isolator (7).
    Fig 23: Upper And Lower Radiator Hoses & Retainer
    GC0152419Courtesy of CHRYSLER GROUP, LLC
  52. Remove the upper radiator hose (2) from the engine.
  53. Disengage the hose retainer (4) and remove the windshield washer fluid reservoir. Refer to RESERVOIR, WINDSHIELD WASHER, REMOVAL .
  54. Remove the lower radiator hose (3) from the engine.
    Fig 24: Return Hose, Lower Supply Hose, Mounting Screw & Coolant Recovery Bottle
    GC0152348Courtesy of CHRYSLER GROUP, LLC
  55. Remove the pressurized coolant bottle (5). Refer to BOTTLE, PRESSURIZED COOLANT, REMOVAL .
    Fig 25: Hydraulic Clutch Line Support Bracket & Bolts
    GC0153302Courtesy of CHRYSLER GROUP, LLC
  56. Remove the two bolts (1) from the hydraulic clutch line support bracket (2).
    Fig 26: Slave Cylinder Bolts
    GC0152820Courtesy of CHRYSLER GROUP, LLC
  57. Remove the two bolts (1) from the hydraulic clutch slave cylinder and reposition the slave cylinder.
    Fig 27: Reverse Lamp Switch Connector
    GC0152745Courtesy of CHRYSLER GROUP, LLC
  58. Disconnect the electrical connector (1) from the reverse lamp switch.
    Fig 28: Ground Strap
    GC0152744Courtesy of CHRYSLER GROUP, LLC
  59. Remove the ground strap (1) from the transmission.
    Fig 29: Shift Selector Cable
    GC0152746Courtesy of CHRYSLER GROUP, LLC
  60. Disconnect the shift selector cable (1) from the lever.
    Fig 30: Cable Retention Clip
    GC0152840Courtesy of CHRYSLER GROUP, LLC
  61. Remove the retainer (1) from the shift selector cable and reposition the cable.
    Fig 31: Shift Cable
    GC0152839Courtesy of CHRYSLER GROUP, LLC
  62. Disconnect the shift cable (1) from lever.
    Fig 32: Cable Mounting Bracket
    GC0152841Courtesy of CHRYSLER GROUP, LLC
  63. Remove the retainer (1) from the shift cable and reposition the cable.
    Fig 33: Battery Cable & Nut
    GC0152405Courtesy of CHRYSLER GROUP, LLC
  64. Remove the nut (2) and the battery cable (1) from the battery terminal.
    Fig 34: A/C Suction Line, Nut, Heater Core Outlet Hose & Inlet Hose
    GC0152409Courtesy of CHRYSLER GROUP, LLC
  65. Disconnect the heater core outlet hose (3) and inlet hose (4) from the heater core.
  66. 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 35: Fuel Line, Hose Retainer & Fuel Vapor Purge Hose
    GC0152408Courtesy of CHRYSLER GROUP, LLC
  67. Disconnect the fuel vapor purge hose (3) from the intake manifold.
  68. Open the hose retainer (1). Disconnect the fuel line (2) from the fuel rail. Refer to FITTING, QUICK CONNECT .
    Fig 36: Vacuum Pump & Connector
    GC0152398Courtesy of CHRYSLER GROUP, LLC
  69. 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.

  70. Remove the vacuum pump (1). Refer to PUMP, VACUUM, REMOVAL .
    Fig 37: Engine Lifting Bracket & Bolts
    GC0152654Courtesy of CHRYSLER GROUP, LLC
  71. 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 38: Engine Hoist & Load-Leveling Lifting Sling
    GC0152420Courtesy of CHRYSLER GROUP, LLC
  72. Reposition the main wire harness over the left frame extension.
  73. 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 39: LH Engine Mount Isolator & Bolts
    GC0152421Courtesy of CHRYSLER GROUP, LLC
    NOTE:

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

  74. Remove the three bolts (2 and 3) and the LH engine mount isolator (1).
    Fig 40: Three Right Side Engine Mount Support Bolts
    GC0152565Courtesy of CHRYSLER GROUP, LLC
    NOTE:

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

  75. Remove three bolts (3) from the RH engine mount isolator (1).
  76. Remove the engine and transmission from the vehicle.
    Fig 41: Starter Assembly, Connector & Fasteners
    GC0153134Courtesy of CHRYSLER GROUP, LLC
    NOTE:

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

  77. Remove the starter assembly (5). Refer to STARTER, REMOVAL .
    Fig 42: Flywheel Dust Cover Bolts
    GC0153313Courtesy of CHRYSLER GROUP, LLC
  78. Remove the two bolts (1) from the flywheel dust cover.
    Fig 43: Transmission Bell Housing Bolts, Nut & Stud
    GC0152757Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The flywheel dust cover is bolted to the oil pan and cannot be removed at this time.

  79. Remove the lower transmission bell housing bolts (3) and nut (1).
    Fig 44: Upper Bell Housing Bolts
    GC0152751Courtesy of CHRYSLER GROUP, LLC
  80. Position a transmission jack under the transmission. Secure the transmission to the jack.
  81. Remove the upper bell housing bolts (1) and separate the transmission from the engine.
    Fig 45: Pressure Plate Bolts
    GC0152711Courtesy of CHRYSLER GROUP, LLC
    NOTE:

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

  82. Remove the clutch pressure plate and disc. Refer to DISC, CLUTCH, REMOVAL .
    Fig 46: Flywheel-To-Crankshaft Bolts
    GC0152723Courtesy of CHRYSLER GROUP, LLC
  83. Remove the flywheel. Refer to FLYWHEEL, REMOVAL .
    Fig 47: Flywheel Dust Cover & Bolt
    GC0153316Courtesy of CHRYSLER GROUP, LLC
  84. Remove the bolt (1) and the flywheel dust cover (2).
    Fig 48: Identifying Drive Belt Tensioners & Assembly With Drive Belt
    GC0152365Courtesy of CHRYSLER GROUP, LLC
  85. Remove the accessory drive belt (4). Refer to BELT, SERPENTINE, REMOVAL .
    Fig 49: Generator & Fasteners
    GC0153159Courtesy of CHRYSLER GROUP, LLC
  86. Remove the generator (3). Refer to GENERATOR, REMOVAL .
    Fig 50: A/C Compressor Assembly
    GC0152542Courtesy of CHRYSLER GROUP, LLC
  87. Remove the A/C compressor (1). Refer to COMPRESSOR, A/C, REMOVAL .
    Fig 51: Oil Level Indicator Tube & Bolt
    GC0152426Courtesy of CHRYSLER GROUP, LLC
  88. Remove the bolt (2) and the oil level indicator tube (1).
    Fig 52: Accessory Mounting Bracket & Fasteners
    GC0152427Courtesy of CHRYSLER GROUP, LLC
  89. Remove the bolt (5) and the ground wire.
  90. Remove the three bolts (3), two nuts (2 and 3) and the accessory mounting bracket (1).
    Fig 53: Screw, Block Heater & Power Cord
    GC0152549Courtesy of CHRYSLER GROUP, LLC
  91. Remove the block heater (3) (if equipped). Refer to HEATER, ENGINE BLOCK, REMOVAL .
    Fig 54: RH Engine Mount Bracket & Bolts
    GC0152463Courtesy of CHRYSLER GROUP, LLC
    NOTE:

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

  92. Install the engine on an engine stand such as OTC® 1726A 1, 000 LB. Capacity Engine Stand or equivalent, and remove the lifting sling.
  93. Remove six bolts (2) and the RH engine mount bracket (1).
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