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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 >> C635 DDCT/C635 Transaxle

C635 DDCT/C635 Transaxle

  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 mount to transaxle bolts.

    Refer to INSULATOR, ENGINE MOUNT, LEFT, INSTALLATION .

  5. Tighten the bolts.

    Refer to SPECIFICATIONS .

    Fig 1: Engine Hoist & Load-Leveling Lifting Sling
    GC0152420Courtesy of CHRYSLER GROUP, LLC
  6. Remove the engine lift (1) and the leveling tool (2).
    Fig 2: Vacuum Pump & Bolts
    GC0152461Courtesy of CHRYSLER GROUP, LLC
  7. Install the vacuum pump (1).

    Refer to PUMP, VACUUM, REMOVAL .

  8. Install the shift cable eyelet to the selector on the transmission.
  9. Raise and support the vehicle.

    Refer to HOISTING, STANDARD PROCEDURE .

  10. Position the exhaust pipe to the catalytic converter outlet. Install a new gasket and nuts.
  11. Install the pipe bracket and bolt.
  12. Tighten the flange bolts.

    Refer to SPECIFICATIONS .

  13. Tighten the exhaust pipe bracket bolt.

    Refer to SPECIFICATIONS .

  14. Install the left and right axle shafts.

    Refer to INSTALLATION .

  15. Install the axle shaft support bearing assembly.
  16. Install the two ball joint pinch bolts. Tighten the bolts to specification.

    Refer to FRONT, SPECIFICATIONS .

  17. Attach the air-conditioning to the bracket near the generator.
  18. Install new  O-rings to the AC line.
  19. Attach the AC lines to the AC compressor.
  20. Lower the vehicle.
    Fig 3: Fuel & Vapor Lines
    GC0159022Courtesy of CHRYSLER GROUP, LLC
  21. Connect the fuel and vapor lines (1) to the fittings.
    Fig 4: EVAP And Fuel Line Retainer & Locks
    GC0158852Courtesy of CHRYSLER GROUP, LLC
  22. 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
  23. Position the Front End Module (FEM) to the frame rails.
  24. Insert the three lower frame rail bolts (2). Repeat both sides.
  25. Install the air-conditioning lines with new seals to the expansion valve. Install the nut and tighten to 20 N.m (15 ft. lbs.).
  26. 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
  27. Install the charge air cooler outlet hose (2). Tighten the bolt (3) to 9 N.m (80 in. lbs.).

    Refer to SPECIFICATIONS .

  28. Tighten the clamp (1) securing the charge air cooler outlet hose to the pipe.
  29. Connect the boost pressure sensor wire harness connector (1).
  30. Install the afterrun pump hoses and secure the clamps in position.
    Fig 7: Cable Connector & Release Tabs
    GC0148010Courtesy of CHRYSLER GROUP, LLC
  31. Attach the shift cable eyelet (1) to the shift lever ball stud.
  32. Raise and support the vehicle.

    Refer to HOISTING, STANDARD PROCEDURE .

    Fig 8: Rear Engine Isolator To Engine Mount Bracket Bolt
    GC0155547Courtesy of CHRYSLER GROUP, LLC
  33. Position rear mount into the crossmember pocket.
  34. Install the through bolt (1) into the crossmember portion of the mount.
  35. Position the front arm of the mount around the bracket (3) and install the through bolt and nut (4 and 2)
  36. Tighten both to 47 N.m (35 ft. lbs.).
  37. Install the rear engine mount isolator (3) to the transmission with the rear engine mount bracket bolt (4) and tightened to 80 N.m (59 ft. lbs.).
  38. Install the rear engine mount bracket (2) with two bolts (1).
  39. Install the rear engine mount bracket bolt and nut (5). Tighten to 80 N.m (59 ft. lbs.).
  40. Install the intermediate shaft and both axle shafts.

    Refer to INSTALLATION .

    Fig 9: Engine Cooling Radiator Components
    GC0158908Courtesy of CHRYSLER GROUP, LLC
  41. Install the cooling module (5) to the FEM. Tighten the mount bolts (3).
  42. Connect the fan power connector (6).
  43. Connect the resistor (1).
    Fig 10: Upper Mounts, Shroud Bolts & Shroud
    GC0158708Courtesy of CHRYSLER GROUP, LLC
  44. Install the air dam (3) by pinching the expanders (1) to secure into the core.
  45. Install the mount bolts (2). Tighten the bolts.
    Fig 11: Upper & Lower Bumper Reinforcement
    GC0153091Courtesy of CHRYSLER GROUP, LLC
  46. Install the bumper reinforcement (1).
    Fig 12: Lower Bumper Reinforcement & Fasteners
    GC0158638Courtesy of CHRYSLER GROUP, LLC
  47. Install the fasteners (2) securing the lower bumper reinforcement (1) to the frame/front end module. Tighten the fasteners to 45 N.m (33 ft. lbs.).
  48. Install the lower radiator hose to the engine.
  49. Install the cross-under pipe.
  50. Engage the oxygen sensor wire harness to the retainer.
  51. Connect the wire harness connectors to the upstream and downstream oxygen sensors.
    Fig 13: Ground Cable & Bolt
    GC0156085Courtesy of CHRYSLER GROUP, LLC
  52. Install the ground cable (2) to the transmission case. Tighten the bolt to 24 N.m (18 ft. lbs.). Install the frame splash shield with three screws.
  53. Install both front inner wheel well splash shields.

    Refer to SHIELD, SPLASH, FRONT WHEELHOUSE, INSTALLATION .

  54. Install both front tire and wheel assemblies.

    Refer to INSTALLATION .

  55. Install the belly pan.

    Refer to BELLY PAN, INSTALLATION .

  56. Lower the vehicle.
  57. Position the battery tray and PCM in the vehicle. Route the wire harness and close the wire harness retainers (3).
  58. Install the ground strap (4) with nut (1) tightened to 5 N.m (44 in. lbs.).
  59. Position the wire harness into wire harness retainers (3) and close retainers.
  60. Install the battery tray.

    Refer to TRAY, BATTERY, INSTALLATION .

  61. Connect the Powertrain Control Module (PCM) harness connectors.
  62. Install the upper radiator hose to the engine.
  63. Lower the vehicle.
    Fig 14: PCV Hose, Vent Hose, Oil Separator Housing & Bolts
    GC0155887Courtesy of CHRYSLER GROUP, LLC
  64. Install the oil separator housing (4) to the cylinder head cover with three bolts (2) tightened to 13 N.m (115 in. lbs.).
  65. Connect the vent hose (3) to the cylinder head cover.
  66. Connect the PCV hose (1) to the intake manifold.
  67. Install the air cleaner body.

    Refer to BODY, AIR CLEANER, INSTALLATION .

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

    Refer to OIL, STANDARD PROCEDURE .

  69. Fill the cooling system.

    Refer to STANDARD PROCEDURE .

  70. Install and connect the battery.

    Refer to BATTERY, INSTALLATION .

  71. Evacuate and charge the refrigerant system.

    Refer to PLUMBING, STANDARD PROCEDURE .

  72. 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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