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Home >> Fiat >> 2016 >> 500 Turbo, Standard Trans >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 3 (1.4L 16-Valve Engine (Service Information) - 500) >> Manifolds >> Manifold, Intake >> Removal >> Removal

Manifold, Intake: Removal: Removal

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  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 .
    Fig 1: Engine Cover
    GC0152354Courtesy of CHRYSLER GROUP, LLC
  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 three bolts (2) and remove the oil separator housing (4) from the cylinder head cover.
    Fig 4: Fuel Line, Hose Retainer & Fuel Vapor Purge Hose
    GC0152408Courtesy of CHRYSLER GROUP, LLC
  8. Disconnect the fuel vapor purge hose (3) from the intake manifold.
  9. Open the hose retainer (1) and disconnect the fuel line (2) from the fuel rail. Refer to FITTING, QUICK CONNECT .
    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 5: PCM Electrical Connectors
    GC0152393Courtesy of CHRYSLER GROUP, LLC
  10. Disconnect and remove the battery. Refer to BATTERY, REMOVAL .
  11. Unlock and disconnect the Powertrain Control Module (PCM) harness connectors (1 and 2).
    Fig 6: Battery Tray, Connectors, Retainers, Nut & Bolts
    GC0152563Courtesy of CHRYSLER GROUP, LLC
  12. Disengage two starter wire harness retainers (6) from the battery tray (3).
  13. Disengage two engine wire harness retainers (4) from the battery tray (3).
  14. Disengage the engine wire harness connector (2) from the battery tray (3) and reposition the wire harness.
  15. Remove the nut (5) and two bolts (1).
    Fig 7: PCM, Retainers, Ground Strap & Nuts
    GC0152394Courtesy of CHRYSLER GROUP, LLC
  16. Open the two wire harness retainers (3) and reposition the wire harness.
  17. Remove the nut (1) and the ground strap (4).
  18. Remove the battery tray with the PCM (2) attached.
    Fig 8: IAT/MAP Sensor, Connector & Bolt
    GC0152437Courtesy of CHRYSLER GROUP, LLC
  19. Unlock and disconnect the IAT/MAP sensor harness connector (1).
    Fig 9: Evaporative Emissions Purge Solenoid Connector, Fuel Injector Wire Harness Connector & Fasteners
    GC0152438Courtesy of CHRYSLER GROUP, LLC
  20. Unlock and disconnect the evaporative emissions purge solenoid harness connector (1).
  21. Unlock and disconnect the fuel injector harness connector (2).
    Fig 10: Electronic Throttle Control, Connector, Clip & Bolts
    GC0152439Courtesy of CHRYSLER GROUP, LLC
  22. Unlock and disconnect the harness connector (3) from the Electronic Throttle Control (ETC) (4) and disengage the ETC harness from the clip (2) on the throttle body.
    Fig 11: Oil Separator Housing Bracket & Fasteners
    GC0152568Courtesy of CHRYSLER GROUP, LLC
  23. Remove two bolts (2), one nut (3) and reposition the oil separator housing bracket (1).
    Fig 12: Vacuum Pump & Bolts
    GC0152461Courtesy of CHRYSLER GROUP, LLC
  24. Disconnect the vacuum line from the vacuum pump (1).
    Fig 13: Lower Air Dam/Belly Pan
    GC0082359Courtesy of CHRYSLER GROUP, LLC
  25. Raise and support the vehicle. Refer to HOISTING .
  26. Remove the belly pan. Refer to BELLY PAN, REMOVAL .
  27. Drain the cooling system. Refer to STANDARD PROCEDURE .
    Fig 14: Tunnel Support Brace & Bolts
    GC0152449Courtesy of CHRYSLER GROUP, LLC
  28. Remove 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.).
    Fig 15: Rear Engine Mount Bracket, Isolator & Fasteners
    GC0153301Courtesy of CHRYSLER GROUP, LLC
  29. If equipped with a manual transmission, remove the rear engine mount bracket bolt (3) and nut (6), loosen the isolator bolt (1) and reposition the rear engine mount isolator (7) away from the bracket (5).
    Fig 16: Two Bolts Of Lower Transmission Mount
    GC0152406Courtesy of CHRYSLER GROUP, LLC
  30. If equipped with an automatic transmission, remove two bolts (4) from the rear engine mount bracket (3), loosen the bolt (1) and reposition the rear engine mount link (5) away from the bracket (3).
    Fig 17: Engine Cooling Fan, Connector & Fasteners
    GC0152367Courtesy of CHRYSLER GROUP, LLC
  31. Remove the engine cooling fan (2). Refer to FAN, COOLING, REMOVAL .
    Fig 18: Right Vertical Brace, Frame Splash Shield & Fasteners
    GC0153366Courtesy of CHRYSLER GROUP, LLC
  32. Remove two bolts (4) and the right vertical brace (5).
  33. Remove two screws (2) from the front wheelhouse splash shield.
  34. Remove three screws (1) and the frame splash shield (3).
    Fig 19: Drive Belt Tensioners & Assembly With Drive Belt Routing
    GC0152365Courtesy of CHRYSLER GROUP, LLC
  35. Remove the accessory drive belt (4). Refer to BELT, SERPENTINE, REMOVAL .
    Fig 20: A/C Compressor & Fasteners
    GC0152459Courtesy of CHRYSLER GROUP, LLC
  36. Remove the A/C compressor (1). Refer to COMPRESSOR, A/C, REMOVAL .
    Fig 21: A/C Suction Line, Nut, Heater Core Outlet Hose & Inlet Hose
    GC0152409Courtesy of CHRYSLER GROUP, LLC
  37. Disconnect the heater core outlet hose (3) and inlet hose (4) from the heater core.
    Fig 22: Wire Harness Retainers
    GC0152434Courtesy of CHRYSLER GROUP, LLC
  38. Open the two wire harness retainers (1) and reposition the wire harness.
    Fig 23: Intake Manifold Flange Bolts
    GC0152435Courtesy of CHRYSLER GROUP, LLC
  39. Remove six of the seven intake manifold flange bolts (1).
    Fig 24: Return Hose, Lower Supply Hose, Mounting Screw & Coolant Recovery Bottle
    GC0152348Courtesy of CHRYSLER GROUP, LLC
  40. Disconnect the lower coolant hose from the radiator.
  41. Reposition the coolant recovery bottle (5). Refer to BOTTLE, PRESSURIZED COOLANT, REMOVAL .
    Fig 25: RH Engine Mount Isolator, Support Bracket & Bolts
    GC0152565Courtesy of CHRYSLER GROUP, LLC
  42. Support the engine with a floor jack positioned under the oil pan.
  43. Remove six bolts (1 and 3) and the RH engine mount isolator (4).
    Fig 26: Intake Manifold & Fasteners
    GC0152436Courtesy of CHRYSLER GROUP, LLC
  44. Slowly lower the engine so that it rolls forward and down.
  45. Remove the remaining intake manifold flange bolt (3), the intake manifold support bolt (2) and remove the intake manifold (1) from the vehicle through the space normally occupied by the battery.
    Fig 27: Intake Manifold Seals
    GC0152454Courtesy of CHRYSLER GROUP, LLC
  46. Remove and discard the four intake manifold seals (1).
  47. Cover the open intake ports to prevent debris from entering the engine.
  48. If required, remove the following components from the intake manifold:
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