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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 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.
Fig 1: Air Cleaner Assembly, Intake Hose, Fittings & Clamp
GC0153787Courtesy 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. Remove the air cleaner body (1). Refer to BODY, AIR CLEANER, REMOVAL .
  3. Recover the refrigerant from the air conditioning 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.
  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. Disengage two starter wire harness retainers (6) from the battery tray (3).
  10. Disengage two engine wire harness retainers (4) from the battery tray (3).
  11. Disengage the engine wire harness connector (2) from the battery tray (3) and reposition the wire harness.
  12. Remove the nut (5) and two bolts (1) and the battery tray (3).
    Fig 5: PCM, Retainers, Ground Strap & Nuts
    GC0152394Courtesy of CHRYSLER GROUP, LLC
  13. Open the two wire harness retainers (3) and reposition the wire harness.
  14. Remove the nut (1) and the ground strap (4).
  15. Remove the battery tray with the PCM (2) attached.
    Fig 6: Lower Air Dam/Belly Pan
    GC0082359Courtesy of CHRYSLER GROUP, LLC
  16. Raise and support the vehicle. Refer to HOISTING .
  17. Remove the belly pan. Refer to BELLY PAN, REMOVAL .
  18. Drain the cooling system. Refer to STANDARD PROCEDURE .
  19. Drain the engine oil. Refer to STANDARD PROCEDURE .
    Fig 7: Tunnel Support Brace & Bolts
    GC0152449Courtesy of CHRYSLER GROUP, LLC
  20. Remove the four bolts (1) and the tunnel support brace (2).
  21. Remove both front tire and wheel assemblies. Refer to REMOVAL .
  22. Remove both front inner wheel well splash shields. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE, REMOVAL .
    Fig 8: Right Vertical Brace, Frame Splash Shield & Fasteners
    GC0153366Courtesy of CHRYSLER GROUP, LLC
    NOTE:

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

  23. Remove two bolts (4) and both right and left vertical braces.
  24. Remove two screws (2) from the wheel house splash shield.
  25. Remove three screws (1) and the frame splash shield (3).
    Fig 9: Front Fascia
    GC0153127Courtesy of CHRYSLER GROUP, LLC
  26. Remove the front fascia (1). Refer to FASCIA, FRONT, REMOVAL .
    Fig 10: Left Headlamp & Fasteners
    GC0153009Courtesy of CHRYSLER GROUP, LLC
  27. Remove the right and left headlamp units (2). Refer to UNIT, HEADLAMP, REMOVAL .
    Fig 11: Cooling Fan Resistor & Fan Assembly
    GC0152401Courtesy of CHRYSLER GROUP, LLC
  28. Disconnect the upper coolant hose from the radiator.
  29. Disconnect the electrical connector from the cooling fan resistor (1).
    Fig 12: Engine Cooling Fan, Connector & Fasteners
    GC0152367Courtesy of CHRYSLER GROUP, LLC
  30. Disconnect the lower coolant hose from the radiator.
  31. Disconnect the cooling fan electrical connector (3).
    Fig 13: A/C Liquid Line, A/C Discharge Line, A/C Condenser Tapping Block & Bolt
    GC0152540Courtesy of CHRYSLER GROUP, LLC
  32. 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).
  33. Separate the A/C liquid line from the A/C discharge line. Remove and discard the dual plain seals.
  34. Install plugs in, or tape over, the opened refrigerant line fittings and condenser ports.
    Fig 14: Latch Cable
    GC0084616Courtesy of CHRYSLER GROUP, LLC
  35. Press down the latch release (3) and remove the hood latch cable (2) from the latch.
    Fig 15: Front Impact Sensor & Connector
    GC0153793Courtesy of CHRYSLER GROUP, LLC
  36. Disconnect the wire harness connector (1) from the right and left front impact sensors (3). Refer to SENSOR, IMPACT, REMOVAL .
    Fig 16: Horn & Connector
    GC0153791Courtesy of CHRYSLER GROUP, LLC
  37. Disconnect the wire harness connector (1) from the horn (2).
    Fig 17: Wire Harness Push Pin
    GC0103127Courtesy of CHRYSLER GROUP, LLC
  38. Disengage the wire harness connector (1) from the ambient air temperature sensor.
    Fig 18: View Of Wire Harness
    GC0103128Courtesy of CHRYSLER GROUP, LLC
  39. Disengage the wire harness retainer (1) from the bottom of the bumper reinforcement.
    Fig 19: Throttle Body Inlet Hose, Turbocharger Outlet Hose & Cooling Fan
    GC0153790Courtesy of CHRYSLER GROUP, LLC
  40. Disconnect the throttle body inlet hose (1) and turbocharger outlet hose (2) at the lower quick disconnects located behind the cooling fan (3).
    Fig 20: Cooling Module Assembly & Fasteners
    GC0157930Courtesy of CHRYSLER GROUP, LLC
  41. 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 21: Front Exhaust Pipe Support Bolt & Flange Nuts
    GC0153120Courtesy of CHRYSLER GROUP, LLC
  42. Raise and support the vehicle. Refer to HOISTING .
  43. Remove the exhaust flange nuts (1).
    Fig 22: Downstream & Upstream Oxygen Sensors With Retainer
    GC0155869Courtesy of CHRYSLER GROUP, LLC
  44. Disconnect the wire harness connectors from the upstream (1) and downstream (2) oxygen sensors.
  45. Disengage the oxygen sensor wire harness from the retainer (3).
    Fig 23: Right Side Axle Shaft
    GC0152661Courtesy of CHRYSLER GROUP, LLC
  46. Remove both axle shafts (1) and intermediate shaft. Refer to REMOVAL .
    Fig 24: Rear Engine Mount Bracket, Isolator & Fasteners
    GC0153301Courtesy of CHRYSLER GROUP, LLC
  47. Remove the rear engine mount bracket bolt (3) and nut (6).
  48. Remove the two bolts (2 and 4) and remove the rear engine mount bracket (5).
  49. Loosen the isolator bolt (1) and reposition the rear engine mount isolator (7).
  50. Lower the vehicle.
    Fig 25: Wire Harness Connector, Rear Washer Hoses & Bolts
    GC0153014Courtesy of CHRYSLER GROUP, LLC
  51. Remove the windshield washer fluid reservoir. Refer to RESERVOIR, WINDSHIELD WASHER, REMOVAL .
    Fig 26: Pressurized Coolant Bottle, Reservoir Hose & Coolant Reservoir Bolts
    GC0156417Courtesy of CHRYSLER GROUP, LLC
  52. Disconnect the after-run pump coolant hoses (2 and 4).
  53. Remove the coolant hose (3) from the pressurized coolant bottle (1).
  54. Remove the two bolts (5) and reposition the pressurized coolant bottle (1).
    Fig 27: EVAP Purge Hose, Charge Air Cooler Outlet Hose, Retaining Clip, Bolt & Wire Harness Connector
    GC0155526Courtesy of CHRYSLER GROUP, LLC
  55. Disconnect the boost pressure sensor wire harness connector (1).
  56. Disengage the EVAP purge hose (4) from the retaining clip (2) and remove the hose from the charge air cooler outlet hose (5).
  57. Loosen the clamp securing the charge air cooler outlet hose to the throttle body.
  58. Remove the bolt (3) and remove the charge air cooler outlet hose (5) from the vehicle.
    Fig 28: Ground Strap
    GC0152744Courtesy of CHRYSLER GROUP, LLC
  59. Remove the ground strap (1) from the transmission.
    Fig 29: Reverse Lamp Switch Connector
    GC0152745Courtesy of CHRYSLER GROUP, LLC
  60. Disconnect reverse lamp switch wire harness connector (1) from the transmission.
    Fig 30: Clutch Slave Cylinder Hose & Retaining Clip
    GC0155856Courtesy of CHRYSLER GROUP, LLC
  61. Pull the retaining clip (1) to disengage the concentric slave cylinder hose (2). Remove and reposition the hose.
    Fig 31: Collars
    GC0157836Courtesy of CHRYSLER GROUP, LLC
  62. Disconnect the shift selector cables from the shift levers.
  63. Pull back on the collars (1) and remove the cables from the mounting bracket.
    Fig 32: Battery Cable & Nut
    GC0152405Courtesy of CHRYSLER GROUP, LLC
  64. Remove the nut (2) and the battery cable (1) from the battery terminal.
    Fig 33: 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 34: Fuel Purge Hose & Hose Retainer
    GC0156457Courtesy of CHRYSLER GROUP, LLC
  67. Open the hose retainer (3) and disconnect the fuel purge hose (2). Refer to FITTING, QUICK CONNECT .
  68. Disconnect the fuel line (1) from the fuel rail. Refer to FITTING, QUICK CONNECT .
    Fig 35: 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 36: 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 37: Engine Hoist & Load-Leveling Lifting Sling
    GC0152420Courtesy of CHRYSLER GROUP, LLC
  72. Attach a load-leveling lifting sling (2) between the front engine mounting bracket, the engine lifting bracket and an engine hoist (1).
    Fig 38: LH Engine Mount Isolator & Bolts
    GC0152421Courtesy of CHRYSLER GROUP, LLC
  73. Remove the three bolts (2 and 3) and the left engine mount isolator (1).
    Fig 39: Right Engine Mount Isolator & Bolts
    GC0155881Courtesy of CHRYSLER GROUP, LLC
  74. Remove three bolts (2) from the right engine mount isolator (3).
  75. Remove the engine and transmission from the vehicle.
    Fig 40: Transmission Bell Housing Bolts, Transmission Stud, Flywheel Dust Cover & Nut
    GC0155729Courtesy of CHRYSLER GROUP, LLC
    NOTE:

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

    NOTE:

    The flywheel dust cover (3) is bolted to the oil pan and cannot be removed at this time.

  76. Remove the two bolts (1) from the flywheel dust cover.
  77. Remove the lower transmission bell housing bolts (2).
  78. Remove the nut (4) from the transmission stud (5).
    Fig 41: Starter Assembly, Connector & Fasteners
    GC0153134Courtesy of CHRYSLER GROUP, LLC
  79. Remove the starter assembly (5). Refer to STARTER, REMOVAL .
    Fig 42: Upper Bell Housing Bolts
    GC0156315Courtesy 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 43: Flywheel Dust Covers & Bolts
    GC0156336Courtesy of CHRYSLER GROUP, LLC
  82. Remove the two bolts (1) and the flywheel dust covers (2 and 3).
    Fig 44: Pressure Plate Bolts
    GC0155963Courtesy of CHRYSLER GROUP, LLC
    NOTE:

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

  83. Remove bolts (1) and the clutch and pressure plate.
    Fig 45: Flywheel-To-Crankshaft Bolts
    GC0152723Courtesy of CHRYSLER GROUP, LLC
  84. Remove bolts (1) and the flywheel.
    Fig 46: 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 47: Generator & Fasteners
    GC0153159Courtesy of CHRYSLER GROUP, LLC
  86. Remove the generator (3). Refer to GENERATOR, REMOVAL .
    Fig 48: A/C Compressor Assembly
    GC0152542Courtesy of CHRYSLER GROUP, LLC
  87. Remove the A/C compressor (1). Refer to COMPRESSOR, A/C, REMOVAL .
    Fig 49: Oil Level Indicator Tube & Bolt
    GC0152426Courtesy of CHRYSLER GROUP, LLC
  88. Remove the bolt (2) and the oil level indicator tube (1).
    Fig 50: Accessory Drive Mounting Bracket, Nuts & Bolts
    GC0155787Courtesy of CHRYSLER GROUP, LLC
  89. Remove the bolt (5) and the ground wire.
  90. Remove the three bolts (4), two nuts (2 and 3) and the accessory drive mounting bracket (1).
    Fig 51: 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 52: RH Engine Mount Bracket & Bolts
    GC0152463Courtesy of CHRYSLER GROUP, LLC
  92. Install the engine on an engine stand and remove the lifting sling.
  93. Remove six bolts (2) and the right engine mount bracket (1).
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