LEMON Manuals: Even more car manuals for everyone
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 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 right engine mount bracket (1) with six bolts (2) tightened to 25 N.m (18 ft. lbs.).
    Fig 2: Screw, Block Heater & Power Cord
    GC0152549Courtesy of CHRYSLER GROUP, LLC
  2. Install the block heater (3) (if equipped).

    Refer to HEATER, ENGINE BLOCK, INSTALLATION .

    Fig 3: Accessory Drive Mounting Bracket, Nuts & Bolts
    GC0155787Courtesy of CHRYSLER GROUP, LLC
  3. Install the accessory drive mounting bracket (1). Tighten the to nuts (2 and 3) and the three bolts (4) 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.).
  4. Install the ground wire and tighten the bolt (5) to 9 N.m (80 in. lbs.).
    Fig 4: Oil Level Indicator Tube & Bolt
    GC0152426Courtesy of CHRYSLER GROUP, LLC
  5. Install the oil level indicator tube (1). Tighten bolt (2) 9 N.m (80 in. lbs.).
    Fig 5: A/C Compressor Assembly
    GC0152542Courtesy of CHRYSLER GROUP, LLC
  6. Install the A/C compressor (1).

    Refer to COMPRESSOR, A/C, INSTALLATION .

    Fig 6: Generator & Fasteners
    GC0153159Courtesy of CHRYSLER GROUP, LLC
  7. Install the generator (3).

    Refer to GENERATOR, INSTALLATION .

    Fig 7: Drive Belt Tensioners & Assembly With Drive Belt Routing
    GC0152365Courtesy of CHRYSLER GROUP, LLC
  8. Install the accessory drive belt (4).

    Refer to BELT, SERPENTINE, INSTALLATION .

    Fig 8: Flywheel-To-Crankshaft Bolts
    GC0152723Courtesy of CHRYSLER GROUP, LLC
  9. Install the flywheel. Using a star pattern, tighten the bolts (1) to 15 N.m (11 ft. lbs.) plus an additional 40 degrees.
    Fig 9: Pressure Plate Bolts
    GC0155963Courtesy of CHRYSLER GROUP, LLC
  10. Using new bolts (1), install the clutch and pressure plate.

    Refer to DISC, CLUTCH, INSTALLATION .

    Fig 10: Flywheel Dust Covers & Bolts
    GC0156336Courtesy of CHRYSLER GROUP, LLC
  11. Install the flywheel dust covers (2 and 3). Tighten bolts (1) to 9 N.m (80 in. lbs.).
    Fig 11: Upper Bell Housing Bolts
    GC0156315Courtesy of CHRYSLER GROUP, LLC
    NOTE:

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

  12. Mate the transmission to the engine. Tighten the upper bell housing bolts (1) to 60 N.m (44 ft. lbs.).
    Fig 12: Transmission Bell Housing Bolts, Transmission Stud, Flywheel Dust Cover & Nut
    GC0155729Courtesy of CHRYSLER GROUP, LLC
  13. Install the nut (4) to the transmission stud (5). Tighten Nut (4) to 60 N.m (44 ft. lbs.).
  14. Install the remaining transmission bell housing bolts (2). Tighten bolts (2) 40 N.m (30 ft. lbs.).
  15. Install the two bolts (1) to the flywheel dust cover and tighten to 9 N.m (80 in. lbs.).
    Fig 13: Starter Assembly, Connector & Fasteners
    GC0153134Courtesy of CHRYSLER GROUP, LLC
  16. Install the starter assembly (5) and connect the electrical wiring (2).

    Refer to STARTER, INSTALLATION .

    Fig 14: Engine Hoist & Load-Leveling Lifting Sling
    GC0152420Courtesy of CHRYSLER GROUP, LLC
  17. Install the engine and transmission into the vehicle.
    Fig 15: Right Engine Mount Isolator & Bolts
    GC0155881Courtesy of CHRYSLER GROUP, LLC
  18. Install three bolts (2) to the right engine mount isolator (1). Tighten the bolts to 60 N.m (44 ft. lbs.).
    Fig 16: LH Engine Mount Isolator & Bolts
    GC0152421Courtesy of CHRYSLER GROUP, LLC
  19. Install the left 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 17: Engine Hoist, Engine Lifting Bracket, Engine Mounting Bracket & Load-Leveling Lifting Sling
    GC0152655Courtesy of CHRYSLER GROUP, LLC
  20. Remove the load-leveling lifting sling (2) from the front engine mounting bracket, the engine lifting bracket and an engine hoist (1).
    Fig 18: Engine Lifting Bracket & Bolts
    GC0152654Courtesy of CHRYSLER GROUP, LLC
    Fig 19: Engine Lifting Bracket
    GC0154236Courtesy of CHRYSLER GROUP, LLC
  21. Remove the (special tool #10299, Bracket, Engine Lifting).
    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 20: Vacuum Pump & Connector
    GC0152398Courtesy of CHRYSLER GROUP, LLC
  22. Install the vacuum pump (1) and wiring harness bracket.

    Refer to PUMP, VACUUM, INSTALLATION .

  23. Connect the main wire harness connector (2) to the engine harness.
    Fig 21: Fuel Purge Hose & Hose Retainer
    GC0156457Courtesy of CHRYSLER GROUP, LLC
  24. Connect the fuel line (1) to the fuel rail.
  25. Connect the fuel vapor purge hose (2) to the intake manifold and close the hose retainer (3).
    Fig 22: A/C Suction Line, Nut, Heater Core Outlet Hose & Inlet Hose
    GC0152409Courtesy of CHRYSLER GROUP, LLC
  26. 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.).
  27. Connect the heater core inlet hose (4) and outlet hose (3) to the heater core.
    Fig 23: Battery Cable & Nut
    GC0152405Courtesy of CHRYSLER GROUP, LLC
  28. Install the battery cable (1) to the battery terminal and tighten the nut (2) to 5 N.m (45 in. lbs.).
    Fig 24: Collars
    GC0157836Courtesy of CHRYSLER GROUP, LLC
  29. Pull back on the collars (1) and install the cables to the mounting bracket.
  30. Connect the shift cables to the levers.
    Fig 25: Clutch Slave Cylinder Hose & Retaining Clip
    GC0155856Courtesy of CHRYSLER GROUP, LLC
  31. Install the hydraulic clutch slave cylinder hose (2) and install the retaining clip (1).
    Fig 26: Reverse Lamp Switch Connector
    GC0152745Courtesy of CHRYSLER GROUP, LLC
  32. Connect the electrical connector (1) to the reverse lamp switch.
    Fig 27: Ground Strap
    GC0152744Courtesy of CHRYSLER GROUP, LLC
  33. Install the ground strap (1) to the transmission.
    Fig 28: EVAP Purge Hose, Charge Air Cooler Outlet Hose, Retaining Clip, Bolt & Wire Harness Connector
    GC0155526Courtesy of CHRYSLER GROUP, LLC
  34. Install the charge air cooler outlet hose (5) to the vehicle. Tighten bolt (3) to 9 N.m (80 in. lbs.).
  35. Tighten the clamp securing the charge air cooler outlet hose to the throttle body.
  36. Install the EVAP purge hose (4) to the charge air cooler outlet hose (5) and engage the hose to the retaining clip (2).
  37. Connect the boost pressure sensor wire harness connector (1).
    Fig 29: Pressurized Coolant Bottle, Reservoir Hose & Coolant Reservoir Bolts
    GC0156417Courtesy of CHRYSLER GROUP, LLC
  38. Install the pressurized coolant bottle (1). Tighten the two bolts (5) to 8 N.m (70 in. lbs.).
  39. Install the coolant hose (3) to the pressurized coolant bottle (1).
  40. Connect the after-run pump coolant hoses (2 and 4).
    Fig 30: Wire Harness Connector, Rear Washer Hoses & Bolts
    GC0153014Courtesy of CHRYSLER GROUP, LLC
  41. Install the windshield washer fluid reservoir.

    Refer to RESERVOIR, WINDSHIELD WASHER, INSTALLATION .

  42. Raise and support the vehicle.

    Refer to HOISTING .

    Fig 31: Rear Engine Mount Bracket, Isolator & Fasteners
    GC0153301Courtesy of CHRYSLER GROUP, LLC
  43. Install the rear engine mount bracket (5) with bolt and nut (2) and bolt (4). Tighten the fasteners to 80 N.m (59 ft. lbs.).
  44. 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.).
  45. Install the isolator bolt (1) and tighten to 130 N.m (96 ft. lbs.).
    Fig 32: Installing Half Shaft
    GC0152930Courtesy of CHRYSLER GROUP, LLC
  46. Install the intermediate shaft and both axle shafts.

    Refer to INSTALLATION .

    Fig 33: Downstream & Upstream Oxygen Sensors With Retainer
    GC0155869Courtesy of CHRYSLER GROUP, LLC
  47. Engage the oxygen sensor wire harness to the retainer (3).
  48. Connect the wire harness connectors to the upstream (1) and downstream (2) oxygen sensors.
    Fig 34: Front Exhaust Pipe Support Bolt & Flange Nuts
    GC0153120Courtesy of CHRYSLER GROUP, LLC
  49. Install the exhaust flange nuts (1). Tighten to 69 N.m (51 ft. lbs.).
  50. Lower the vehicle.
    Fig 35: Cooling Module Assembly & Fasteners
    GC0157930Courtesy of CHRYSLER GROUP, LLC
  51. 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 36: Throttle Body Inlet Hose, Turbocharger Outlet Hose & Cooling Fan
    GC0153790Courtesy of CHRYSLER GROUP, LLC
  52. Connect the throttle body inlet hose (1) and turbocharger outlet hose (2) at the lower quick connects located behind the cooling fan (3).
    Fig 37: View Of Wire Harness
    GC0103128Courtesy of CHRYSLER GROUP, LLC
  53. Engage the wire harness retainer (1) to the bottom of the bumper reinforcement.
    Fig 38: Wire Harness Push Pin
    GC0103127Courtesy of CHRYSLER GROUP, LLC
  54. Connect the wire harness connector (1) to the ambient air temperature sensor.
    Fig 39: Horn & Connector
    GC0153791Courtesy of CHRYSLER GROUP, LLC
  55. Connect the wire harness connector (1) to the horn (2).
    Fig 40: Front Impact Sensor & Connector
    GC0153793Courtesy of CHRYSLER GROUP, LLC
  56. Connect the wire harness connector (2) to the right and left front impact sensors (1).

    Refer to SENSOR, IMPACT, INSTALLATION .

    Fig 41: Latch Cable
    GC0084616Courtesy of CHRYSLER GROUP, LLC
  57. Press down the latch release (3) and install the hood latch cable (2) to the latch.
    Fig 42: A/C Liquid Line, A/C Discharge Line, A/C Condenser Tapping Block & Bolt
    GC0152540Courtesy of CHRYSLER GROUP, LLC
  58. 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 43: Engine Cooling Fan, Connector & Fasteners
    GC0152367Courtesy of CHRYSLER GROUP, LLC
  59. Connect the lower coolant hose to the radiator.
  60. Connect the cooling fan wire harness connector (3).
    Fig 44: Cooling Fan Resistor & Fan Assembly
    GC0152401Courtesy of CHRYSLER GROUP, LLC
  61. Connect the upper coolant hose to the radiator.
  62. Connect the wire harness connector to the cooling fan resistor (1).
    Fig 45: Left Headlamp & Fasteners
    GC0153009Courtesy of CHRYSLER GROUP, LLC
  63. Install the right and left headlamp units (2).

    Refer to UNIT, HEADLAMP, INSTALLATION .

    Fig 46: Front Fascia
    GC0153127Courtesy of CHRYSLER GROUP, LLC
  64. Install the front fascia (1).

    Refer to FASCIA, FRONT, INSTALLATION .

    Fig 47: Right Vertical Brace, Frame Splash Shield & Fasteners
    GC0153366Courtesy of CHRYSLER GROUP, LLC
    NOTE:

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

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

    Refer to SHIELD, SPLASH, FRONT WHEELHOUSE, INSTALLATION .

  68. Install both front tire and wheel assemblies.

    Refer to INSTALLATION .

  69. Install the tunnel support brace (2). Tighten bolts (1) to 100 N.m (74 ft. lb.).
    Fig 49: Lower Air Dam/Belly Pan
    GC0082359Courtesy of CHRYSLER GROUP, LLC
  70. Install the belly pan.

    Refer to BELLY PAN, INSTALLATION .

    Fig 50: PCM, Retainers, Ground Strap & Nuts
    GC0152394Courtesy of CHRYSLER GROUP, LLC
  71. Position the battery tray and PCM in the vehicle. Route the wire harness and close the wire harness retainers (3).
  72. Install the ground strap (4) with nut (1) tightened to 5 N.m (44 in. lbs.).
  73. Position the wire harness into wire harness retainers (3) and close retainers.
    Fig 51: Battery Tray, Connectors, Retainers, Nut & Bolts
    GC0152563Courtesy of CHRYSLER GROUP, LLC
  74. Install the battery tray (3). Tightened the one nut (5) and two bolts (1) to 25 N.m (18 ft. lbs.).
  75. Engage the engine wire harness connector (2) to the battery tray (3).
  76. Engage two engine wire harness retainers (4) to the battery tray (3).
  77. Engage two starter wire harness retainers (6) to the battery tray (3).
    Fig 52: PCM Electrical Connectors
    GC0152393Courtesy of CHRYSLER GROUP, LLC
  78. Connect the Powertrain Control Module (PCM) harness connectors (1 and 2).
  79. Install the upper radiator hose to the engine.
  80. Install the lower radiator hose to the engine.
  81. Fill the transmission with the proper fluid to the correct level. Refer to FLUID .
  82. Lower the vehicle.
    Fig 53: PCV Hose, Vent Hose, Oil Separator Housing & Bolts
    GC0155887Courtesy of CHRYSLER GROUP, LLC
  83. Install the oil separator housing (4) to the cylinder head cover with three bolts (2) tightened to 13 N.m (115 in. lbs.).
  84. Connect the vent hose (3) to the cylinder head cover.
  85. Connect the PCV hose (1) to the intake manifold.
    Fig 54: Air Cleaner Assembly, Intake Hose, Fittings & Clamp
    GC0153787Courtesy of CHRYSLER GROUP, LLC
  86. Install the air cleaner body (1).

    Refer to BODY, AIR CLEANER, INSTALLATION .

  87. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level.

    Refer to STANDARD PROCEDURE .

  88. Fill the transmission.

    Refer to FLUID .

  89. Fill the cooling system.

    Refer to STANDARD PROCEDURE .

  90. Install and connect the battery.

    Refer to BATTERY, INSTALLATION .

  91. Evacuate and charge the refrigerant system.

    Refer to STANDARD PROCEDURE .

  92. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level.

    Refer to STANDARD PROCEDURE .

  93. 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.

scientia non olet · About LEMON Manuals