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Home >> Fiat >> 2016 >> 500 Turbo, Standard Trans >> Repair and Diagnosis >> External Pages >> Different car >> Section 25 (1.4L 16-Valve Turbo Engine (Service Information) 500) >> Installation >> With Automatic Transmission

With Automatic Transmission

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Fig 1: Engine Hoist & Load-Leveling Lifting Sling
GC0152420Courtesy of CHRYSLER GROUP, LLC
  1. Position vehicle height to allow the engine to be installed into the engine compartment.
  2. With the help of an assistant, align the engine/transmission assembly into the correct mount positions.
    NOTE:

    Make sure the air-conditioning lines are correctly routed while lowering the engine into the compartment. Guide the engine past the air-conditioning lines.

  3. Install the right engine mount. Refer to INSULATOR, ENGINE MOUNT, RIGHT, INSTALLATION .
  4. Install the left engine mount. Refer to INSULATOR, ENGINE MOUNT, LEFT, INSTALLATION .
  5. Remove the engine lift (1) and the leveling tool (2).
    Fig 2: Engine Lifting Bracket & Bolts
    GC0152654Courtesy of CHRYSLER GROUP, LLC
  6. Remove the (special tool #10299, Bracket, Engine Lifting) (1).
    Fig 3: Engine Lifting Bracket
    GC0154236Courtesy 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.

    Fig 4: Vacuum Pump & Bolts
    GC0152461Courtesy of CHRYSLER GROUP, LLC
  7. Install the vacuum pump (1). Refer to PUMP, VACUUM, REMOVAL .
    Fig 5: Fuel Purge Hose & Hose Retainer
    GC0156457Courtesy of CHRYSLER GROUP, LLC
  8. Connect the fuel line (1) to the fuel rail.
  9. Connect the fuel vapor purge hose (2) to the intake manifold and close the hose retainer (3).
    Fig 6: A/C Suction Line, Nut, Heater Core Outlet Hose & Inlet Hose
    GC0152409Courtesy of CHRYSLER GROUP, LLC
  10. 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.).
  11. Connect the heater core inlet hose (4) and outlet hose (3) to the heater core.
    Fig 7: Bracket, Gearshift Cable, Manual Valve Lever & TCM Wire Harness Connector
    GC0168972Courtesy of CHRYSLER GROUP, LLC
  12. Install the gearshift cable (2) to the bracket (1).
  13. Connect the gearshift cable (2) to the transmission manual valve lever (3).
  14. Connect the wire harness connector (4) to the Transmission Control Module (TCM).
    Fig 8: Bolt & Ground Strap
    GC0168960Courtesy of CHRYSLER GROUP, LLC
  15. Install the ground cable (1) to the transmission case. Tighten the bolt (2) to 9 N.m (80 in. lbs.).
    Fig 9: EVAP Purge Hose, Charge Air Cooler Outlet Hose, Retaining Clip, Bolt & Wire Harness Connector
    GC0155526Courtesy of CHRYSLER GROUP, LLC
  16. Install the charge air cooler outlet hose (5) to the vehicle. Tighten bolt (3) to 9 N.m (80 in. lbs.).
  17. Tighten the clamp securing the charge air cooler outlet hose to the throttle body.
  18. Install the EVAP purge hose (4) to the charge air cooler outlet hose (5) and engage the hose to the retaining clip (2).
  19. Connect the boost pressure sensor wire harness connector (1).
    Fig 10: Pressurized Coolant Bottle, Reservoir Hose & Coolant Reservoir Bolts
    GC0156417Courtesy of CHRYSLER GROUP, LLC
  20. Install the pressurized coolant bottle (1). Tighten the two bolts (5) to 8 N.m (70 in. lbs.).
  21. Install the coolant hose (3) to the pressurized coolant bottle (1).
  22. Connect the after-run pump coolant hoses (2 and 4).
    Fig 11: Wire Harness Connector, Rear Washer Hoses & Bolts
    GC0153014Courtesy of CHRYSLER GROUP, LLC
  23. Install the windshield washer fluid reservoir.

    Refer to RESERVOIR, WINDSHIELD WASHER, INSTALLATION .

    Fig 12: Two Bolts Of Lower Transmission Mount
    GC0152406Courtesy of CHRYSLER GROUP, LLC
  24. Raise and support the vehicle. Refer to HOISTING .
  25. Install the rear engine mount. Refer to INSULATOR, ENGINE MOUNT, REAR, INSTALLATION .
    Fig 13: Installing Half Shaft
    GC0152930Courtesy of CHRYSLER GROUP, LLC
  26. Install the intermediate shaft and both axle shafts.

    Refer to INSTALLATION .

    Fig 14: Downstream & Upstream Oxygen Sensors With Retainer
    GC0155869Courtesy of CHRYSLER GROUP, LLC
  27. Engage the oxygen sensor wire harness to the retainer (3).
  28. Connect the wire harness connectors to the upstream (1) and downstream (2) oxygen sensors.
    Fig 15: Catalytic Converter, Support Mount & Bolts
    GC0153601Courtesy of CHRYSLER GROUP, LLC
  29. Position the exhaust pipe to the catalytic converter outlet. Install a new gasket and nuts.
  30. Install the pipe bracket and bolt.
  31. Tighten the flange bolts to the proper specification. Refer to TORQUE SPECIFICATIONS .
  32. Tighten the exhaust pipe bracket bolt to the proper specification. Refer to TORQUE SPECIFICATIONS .
    Fig 16: Cooling Module Assembly & Fasteners
    GC0157930Courtesy of CHRYSLER GROUP, LLC
  33. Lower the vehicle.
  34. Install the front cooling module assembly (3) with the lower frame members attached using four bolts (1) and eight bolts and washers (2). Tighten the eight bolts (2) to 45 N.m (33 ft. lb.) and tighten the four bolts (1) to 24 N.m (18 ft. lb.).
    Fig 17: Throttle Body Inlet Hose, Turbocharger Outlet Hose & Cooling Fan
    GC0153790Courtesy of CHRYSLER GROUP, LLC
  35. Connect the throttle body inlet hose (1) and turbocharger outlet hose (2) at the lower quick connects located behind the cooling fan (3).
    Fig 18: View Of Wire Harness
    GC0103128Courtesy of CHRYSLER GROUP, LLC
  36. Engage the wire harness retainer (1) to the bottom of the bumper reinforcement.
    Fig 19: Wire Harness Push Pin
    GC0103127Courtesy of CHRYSLER GROUP, LLC
  37. Connect the wire harness connector (1) to the ambient air temperature sensor.
    Fig 20: Horn & Connector
    GC0153791Courtesy of CHRYSLER GROUP, LLC
  38. Connect the wire harness connector (1) to the horn (2).
    Fig 21: Front Impact Sensor & Connector
    GC0153793Courtesy of CHRYSLER GROUP, LLC
  39. Connect the wire harness connector (2) to the right and left front impact sensors (1).

    Refer to SENSOR, IMPACT, INSTALLATION .

    Fig 22: Latch Cable
    GC0084616Courtesy of CHRYSLER GROUP, LLC
  40. Press down the latch release (3) and install the hood latch cable (2) to the latch.
    Fig 23: A/C Liquid Line, A/C Discharge Line, A/C Condenser Tapping Block & Bolt
    GC0152540Courtesy of CHRYSLER GROUP, LLC
  41. 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 24: Engine Cooling Fan, Connector & Fasteners
    GC0152367Courtesy of CHRYSLER GROUP, LLC
  42. Connect the lower coolant hose to the radiator.
  43. Connect the cooling fan wire harness connector (3).
    Fig 25: Cooling Fan Resistor & Fan Assembly
    GC0152401Courtesy of CHRYSLER GROUP, LLC
  44. Connect the upper coolant hose to the radiator.
  45. Connect the wire harness connector to the cooling fan resistor (1).
    Fig 26: Left Headlamp & Fasteners
    GC0153009Courtesy of CHRYSLER GROUP, LLC
  46. Install the right and left headlamp units (2).

    Refer to UNIT, HEADLAMP, INSTALLATION .

    Fig 27: Front Fascia
    GC0153127Courtesy of CHRYSLER GROUP, LLC
  47. Install the front fascia (1).

    Refer to FASCIA, FRONT, INSTALLATION .

    Fig 28: Right Vertical Brace, Frame Splash Shield & Fasteners
    GC0153366Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Right vertical brace shown in illustration, left vertical brace similar.

  48. Install the frame splash shield (3) with three screws (1).
  49. Install the right and left vertical brace (5) with two bolts (4) tightened to 45 N.m (33 ft. lbs.).
    Fig 29: Tunnel Support Brace & Bolts
    GC0152449Courtesy of CHRYSLER GROUP, LLC
  50. Install both front inner wheel well splash shields.

    Refer to SHIELD, SPLASH, FRONT WHEELHOUSE, INSTALLATION .

  51. Install both front tire and wheel assemblies.

    Refer to INSTALLATION .

  52. Install the tunnel support brace (2). Tighten bolts (1) to 100 N.m (74 ft. lb.).
    Fig 30: Lower Air Dam/Belly Pan
    GC0082359Courtesy of CHRYSLER GROUP, LLC
  53. Install the belly pan. Refer to BELLY PAN, INSTALLATION .
    Fig 31: Battery Tray, Connectors, Retainers, Nut & Bolts
    GC0152563Courtesy of CHRYSLER GROUP, LLC
  54. Lower the vehicle.
  55. Install the battery tray (3) and PCM in the vehicle. Route the wire harness and close the wire harness retainers. Refer to TRAY, BATTERY, INSTALLATION .
    Fig 32: PCM Electrical Connectors
    GC0152393Courtesy of CHRYSLER GROUP, LLC
  56. Engage and lock the Powertrain Control Module (PCM) harness connectors.
  57. Install the upper radiator hose to the engine.
  58. Install the lower radiator hose to the engine.
  59. Fill the transmission with the proper fluid to the correct level.
    Fig 33: PCV Hose, Vent Hose, Oil Separator Housing & Bolts
    GC0155887Courtesy of CHRYSLER GROUP, LLC
  60. Lower the vehicle.
  61. Install the oil separator housing (4) to the cylinder head cover with three bolts (2) tightened to 13 N.m (115 in. lbs.).
  62. Connect the vent hose (3) to the cylinder head cover.
  63. Connect the PCV hose (1) to the intake manifold.
    Fig 34: Air Cleaner Assembly, Intake Hose, Fittings & Clamp
    GC0153787Courtesy of CHRYSLER GROUP, LLC
  64. Install the air cleaner body (1). Refer to BODY, AIR CLEANER, INSTALLATION .
  65. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to STANDARD PROCEDURE .
  66. Fill the cooling system. Refer to STANDARD PROCEDURE .
  67. Install and connect the battery. Refer to BATTERY, INSTALLATION .
  68. Evacuate and charge the refrigerant system. Refer to STANDARD PROCEDURE .
  69. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to STANDARD PROCEDURE .
  70. The Clear Misfire TLC Miscellaneous Function 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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