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Home >> Fiat >> 2016 >> 500L Easy, Automatic Trans >> Repair and Diagnosis >> Engine Mechanical >> Blowers, Superchargers & Turbochargers >> 1.4L Turbo Engine (Service Information) 500L >> Installation >> Aw60T/6F25 Transaxle

Aw60T/6F25 Transaxle

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: Vacuum Pump & Bolts
    GC0152461Courtesy of CHRYSLER GROUP, LLC
  6. Install the vacuum pump (1). Refer to PUMP, VACUUM, REMOVAL .
  7. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
  8. Position the exhaust pipe to the catalytic converter outlet. Install a new gasket and nuts.
  9. Install the pipe bracket and bolt.
  10. Tighten the flange bolts. Refer to SPECIFICATIONS .
  11. Tighten the exhaust pipe bracket bolt. Refer to SPECIFICATIONS .
  12. Install the left and right axle shafts. Refer to INSTALLATION .
  13. Install the axle shaft support bearing assembly.
  14. Install the two ball joint pinch bolts. Tighten the bolts to specification. Refer to FRONT, SPECIFICATIONS .
  15. Install the air-conditioning line support bracket at the compressor.
  16. Install new  O-rings to the AC line.
  17. Attach the AC lines to the AC compressor.
    Fig 3: Fuel & Vapor Lines
    GC0159022Courtesy of CHRYSLER GROUP, LLC
  18. Lower the vehicle.
  19. Connect the fuel and vapor lines (1) to the fittings.
    Fig 4: EVAP And Fuel Line Retainer & Locks
    GC0158852Courtesy of CHRYSLER GROUP, LLC
  20. Release the line retainer. Insert the fresh air, fuel liquid and vapor lines into the retainer (1). Lock the retainer.
    Fig 5: FEM Lower Mounts, Front End Module & Nut
    GC0158889Courtesy of CHRYSLER GROUP, LLC
  21. Position the Front End Module (FEM) to the frame rails.
  22. Insert the three lower frame rail bolts (2). Repeat both sides.
  23. Install the air-conditioning lines with new seals to the expansion valve. Install the nut and tighten to 20 N.m (15 ft. lbs.).
  24. Connect the heater core inlet hose and outlet hose to the heater core fittings.
    Fig 6: Charge Air Cooler Hose, Inlet Quick Connect, Bolt & Clamp
    GC0155791Courtesy of CHRYSLER GROUP, LLC
  25. Install the charge air cooler outlet hose (2). Tighten the bolt (3) to 9 N.m (80 in. lbs.).
  26. Tighten the clamp (1) securing the charge air cooler outlet hose to the pipe.
  27. Connect the boost pressure sensor wire harness connector.
  28. Install the afterrun pump hoses and secure the clamps in position.
    Fig 7: Bracket, Gearshift Cable, Manual Valve Lever & TCM Wire Harness Connector
    GC0168972Courtesy of CHRYSLER GROUP, LLC
  29. Install the gearshift cable (2) to the bracket (1).
  30. Connect the gearshift cable (2) to the transmission manual valve lever (3).
  31. Connect the wire harness connector (4) to the Transmission Control Module (TCM).
    Fig 8: Rear Engine Mount & Bolts
    GC0152406Courtesy of CHRYSLER GROUP, LLC
  32. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
  33. Install the rear engine mount. Refer to INSULATOR, ENGINE MOUNT, REAR, INSTALLATION .
  34. Install the intermediate shaft and both axle shafts. Refer to INSTALLATION .
    Fig 9: Engine Cooling Radiator Components
    GC0158908Courtesy of CHRYSLER GROUP, LLC
  35. Install the cooling module (5) to the FEM. Tighten the mount bolts (3).
  36. Connect the cooling fan motor harness connector (6).
  37. Connect the cooling fan resistor harness connector (1).
    Fig 10: Upper Mounts, Shroud Bolts & Shroud
    GC0158708Courtesy of CHRYSLER GROUP, LLC
  38. Install the air dam (3) by pinching the expanders (1) to secure into the core.
  39. Install and tighten the mount bolts (2).
    Fig 11: Upper & Lower Bumper Reinforcement
    GC0153091Courtesy of CHRYSLER GROUP, LLC
  40. Install the bumper reinforcement (1).
    Fig 12: Lower Bumper Reinforcement & Fasteners
    GC0158638Courtesy of CHRYSLER GROUP, LLC
  41. Install the fasteners (2) securing the lower bumper reinforcement to the frame/front end module (1). Tighten the fasteners to 45 N.m (33 ft. lbs.).
  42. Install the lower radiator hose to the engine.
  43. Install the cross-under pipe.
  44. Engage the oxygen sensor wire harness to the retainer.
  45. Connect the wire harness connectors to the upstream and downstream oxygen sensors.
    Fig 13: Bolt & Ground Strap
    GC0168960Courtesy of CHRYSLER GROUP, LLC
  46. Install the ground cable (1) to the transmission case. Tighten the bolt (2) to 9 N.m (80 in. lbs.). Install the frame splash shield with three screws.
  47. Install both front inner wheel well splash shields. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE, INSTALLATION .
  48. Install both front tire and wheel assemblies. Refer to INSTALLATION .
  49. Install the belly pan. Refer to BELLY PAN, INSTALLATION .
  50. Lower the vehicle.
  51. Position the battery tray and PCM in the vehicle. Route the wire harness and close the wire harness retainers (3).
  52. Install the ground strap (4) with nut (1) tightened to 5 N.m (44 in. lbs.).
  53. Position the wire harness into wire harness retainers (3) and close retainers.
  54. Install the battery tray. Refer to TRAY, BATTERY, INSTALLATION .
  55. Connect the Powertrain Control Module (PCM) harness connectors.
  56. Install the upper radiator hose to the engine.
  57. Lower the vehicle.
    Fig 14: PCV Hose, Vent Hose, Oil Separator Housing & Bolts
    GC0155887Courtesy of CHRYSLER GROUP, LLC
  58. Install the oil separator housing (4) to the cylinder head cover with three bolts (2) tightened to 13 N.m (115 in. lbs.).
  59. Connect the vent hose (3) to the cylinder head cover.
  60. Connect the PCV hose (1) to the intake manifold.
  61. Install the air cleaner body. Refer to BODY, AIR CLEANER, INSTALLATION .
  62. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to OIL, STANDARD PROCEDURE .
  63. Fill the cooling system. Refer to STANDARD PROCEDURE .
  64. Install and connect the battery. Refer to BATTERY, INSTALLATION .
  65. Evacuate and charge the refrigerant system. Refer to PLUMBING, STANDARD PROCEDURE .
  66. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to STANDARD PROCEDURE .
    NOTE:

    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 STANDARD PROCEDURE .

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