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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) >> 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.
Fig 1: Air Cleaner Assembly, Intake Hose, Fittings & Clamp
GC0153787Courtesy of CHRYSLER GROUP, LLC
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.

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. Remove the air cleaner body (1). Refer to BODY, AIR CLEANER, REMOVAL .
  3. Recover the refrigerant from the refrigerant system. Refer to STANDARD PROCEDURE .
    Fig 2: PCV Hose, Vent Hose, Oil Separator Housing & Bolts
    GC0155887Courtesy of CHRYSLER GROUP, LLC
  4. Disconnect the PCV hose (1) from the intake manifold and set aside.
  5. Disconnect the vent hose (3) from the cylinder head cover.
  6. Remove the three bolts (2) and remove the oil separator housing (4) from the cylinder head cover.
    Fig 3: 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.

  7. Disconnect and remove the battery. Refer to BATTERY, REMOVAL .
  8. Disconnect the Powertrain Control Module (PCM) harness connectors (1 and 2).
    Fig 4: Battery Tray, Connectors, Retainers, Nut & Bolts
    GC0152563Courtesy of CHRYSLER GROUP, LLC
  9. Remove the battery tray assembly. Refer to TRAY, BATTERY, REMOVAL .
    Fig 5: Lower Air Dam/Belly Pan
    GC0082359Courtesy of CHRYSLER GROUP, LLC
  10. Raise and support the vehicle. Refer to HOISTING .
  11. Remove the belly pan. Refer to BELLY PAN, REMOVAL .
  12. Drain the cooling system. Refer to STANDARD PROCEDURE .
  13. Drain the engine oil. Refer to STANDARD PROCEDURE .
    Fig 6: Tunnel Support Brace & Bolts
    GC0152449Courtesy of CHRYSLER GROUP, LLC
  14. Remove the four bolts (1) and the tunnel support brace (2).
  15. Remove both front tire and wheel assemblies. Refer to REMOVAL .
  16. Remove both front inner wheel well splash shields. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE, REMOVAL .
    Fig 7: Right Vertical Brace, Frame Splash Shield & Fasteners
    GC0153366Courtesy of CHRYSLER GROUP, LLC
    NOTE:

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

  17. Remove two bolts (4) and both right and left vertical braces.
  18. Remove two screws (2) from the wheel house splash shield.
  19. Remove three screws (1) and the frame splash shield (3).
    Fig 8: Front Fascia
    GC0153127Courtesy of CHRYSLER GROUP, LLC
  20. Remove the front fascia (1). Refer to FASCIA, FRONT, REMOVAL .
    Fig 9: Left Headlamp & Fasteners
    GC0153009Courtesy of CHRYSLER GROUP, LLC
  21. Remove the right and left headlamp units (2). Refer to UNIT, HEADLAMP, REMOVAL .
    Fig 10: Cooling Fan Resistor & Fan Assembly
    GC0152401Courtesy of CHRYSLER GROUP, LLC
  22. Disconnect the upper coolant hose from the radiator.
  23. Disconnect the electrical connector from the cooling fan resistor (1).
    Fig 11: Engine Cooling Fan, Connector & Fasteners
    GC0152367Courtesy of CHRYSLER GROUP, LLC
  24. Disconnect the lower coolant hose from the radiator.
  25. Disconnect the cooling fan electrical connector (3).
    Fig 12: A/C Liquid Line, A/C Discharge Line, A/C Condenser Tapping Block & Bolt
    GC0152540Courtesy of CHRYSLER GROUP, LLC
  26. 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).
  27. Separate the A/C liquid line from the A/C discharge line. Remove and discard the dual plain seals.
  28. Install plugs in, or tape over, the opened refrigerant line fittings and condenser ports.
    Fig 13: Latch Cable
    GC0084616Courtesy of CHRYSLER GROUP, LLC
  29. Press down the latch release (3) and remove the hood latch cable (2) from the latch.
    Fig 14: Front Impact Sensor & Connector
    GC0153793Courtesy of CHRYSLER GROUP, LLC
  30. Disconnect the wire harness connector (1) from the right and left front impact sensors (3). Refer to SENSOR, IMPACT, REMOVAL .
    Fig 15: Horn & Connector
    GC0153791Courtesy of CHRYSLER GROUP, LLC
  31. Disconnect the wire harness connector (1) from the horn (2).
    Fig 16: Wire Harness Push Pin
    GC0103127Courtesy of CHRYSLER GROUP, LLC
  32. Disengage the wire harness connector (1) from the ambient air temperature sensor.
    Fig 17: View Of Wire Harness
    GC0103128Courtesy of CHRYSLER GROUP, LLC
  33. Disengage the wire harness retainer (1) from the bottom of the bumper reinforcement.
    Fig 18: Throttle Body Inlet Hose, Turbocharger Outlet Hose & Cooling Fan
    GC0153790Courtesy of CHRYSLER GROUP, LLC
  34. Disconnect the throttle body inlet hose (1) and turbocharger outlet hose (2) at the lower quick disconnects located behind the cooling fan (3).
    Fig 19: Cooling Module Assembly & Fasteners
    GC0157930Courtesy of CHRYSLER GROUP, LLC
  35. Remove the four bolts (1), eight bolts and washers (2), and the cooling module assembly (3) from the vehicle with the lower frame members attached.
    Fig 20: Catalytic Converter, Support Mount & Bolts
    GC0153601Courtesy of CHRYSLER GROUP, LLC
  36. Remove the exhaust pipe from the catalytic converter outlet.
  37. Remove the exhaust flange nuts and the flange gasket.
    Fig 21: Downstream & Upstream Oxygen Sensors With Retainer
    GC0155869Courtesy of CHRYSLER GROUP, LLC
  38. Disconnect the wire harness connectors from the upstream (1) and downstream (2) oxygen sensors.
  39. Disengage the oxygen sensor wire harness from the retainer (3).
    Fig 22: Right Side Axle Shaft
    GC0152661Courtesy of CHRYSLER GROUP, LLC
  40. Remove both axle shafts (1) and intermediate shaft. Refer to REMOVAL .
  41. Remove the rear engine mount. Refer to INSULATOR, ENGINE MOUNT, REAR, REMOVAL .
    Fig 23: Wire Harness Connector, Rear Washer Hoses & Bolts
    GC0153014Courtesy of CHRYSLER GROUP, LLC
  42. Lower the vehicle.
  43. Remove the windshield washer fluid reservoir. Refer to RESERVOIR, WINDSHIELD WASHER, REMOVAL .
    Fig 24: Pressurized Coolant Bottle, Reservoir Hose & Coolant Reservoir Bolts
    GC0156417Courtesy of CHRYSLER GROUP, LLC
  44. Disconnect the after-run pump coolant hoses (2 and 4).
  45. Remove the coolant hose (3) from the pressurized coolant bottle (1).
  46. Remove the two bolts (5) and reposition the pressurized coolant bottle (1).
    Fig 25: EVAP Purge Hose, Charge Air Cooler Outlet Hose, Retaining Clip, Bolt & Wire Harness Connector
    GC0155526Courtesy of CHRYSLER GROUP, LLC
  47. Disconnect the boost pressure sensor wire harness connector (1).
  48. Disengage the EVAP purge hose (4) from the retaining clip (2) and remove the hose from the charge air cooler outlet hose (5).
  49. Loosen the clamp securing the charge air cooler outlet hose to the throttle body.
  50. Remove the bolt (3) and remove the charge air cooler outlet hose (5) from the vehicle.
    Fig 26: Bolt & Ground Strap
    GC0168960Courtesy of CHRYSLER GROUP, LLC
  51. Remove the bolt (2) and the ground strap (1) from the transmission.
    Fig 27: Bracket, Gearshift Cable, Manual Valve Lever & TCM Wire Harness Connector
    GC0168972Courtesy of CHRYSLER GROUP, LLC
  52. Disconnect the wire harness connector (4) from the Transmission Control Module (TCM).
  53. Disconnect the gearshift cable (2) from the transmission manual valve lever (3).
  54. Remove the gearshift cable (2) from the bracket (1).
    Fig 28: A/C Suction Line, Nut, Heater Core Outlet Hose & Inlet Hose
    GC0152409Courtesy of CHRYSLER GROUP, LLC
  55. Disconnect the heater core outlet hose (3) and inlet hose (4) from the heater core.
  56. 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 29: Fuel Purge Hose & Hose Retainer
    GC0156457Courtesy of CHRYSLER GROUP, LLC
  57. Open the hose retainer (3) and disconnect the fuel purge hose (2). Refer to FITTING, QUICK CONNECT .
  58. Disconnect the fuel line (1) from the fuel rail. Refer to FITTING, QUICK CONNECT .
    Fig 30: Vacuum Pump & Bolts
    GC0152461Courtesy of CHRYSLER GROUP, LLC
    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.

  59. Remove the vacuum pump (1). Refer to PUMP, VACUUM, REMOVAL .
    Fig 31: Engine Lifting Bracket & Bolts
    GC0152654Courtesy of CHRYSLER GROUP, LLC
  60. 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 32: Engine Hoist & Load-Leveling Lifting Sling
    GC0152420Courtesy of CHRYSLER GROUP, LLC
  61. Install the engine leveling/lifting device (2). Position an appropriate lifting tool (1) to the leveler.
  62. Lift the engine enough to safely unbolt the transmission and engine mounts.
  63. Remove the left engine mount. Refer to INSULATOR, ENGINE MOUNT, LEFT, REMOVAL .
  64. Remove the right engine mount. Refer to INSULATOR, ENGINE MOUNT, RIGHT, REMOVAL .
  65. Lift the engine and transmission assembly from the vehicle.
    NOTE:

    Make sure the air-conditioning lines are free of the moving components so they are not caught when lifting.

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