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Home >> Fiat >> 2016 >> 500L Lounge >> Repair and Diagnosis >> Engine Mechanical >> Blowers, Superchargers & Turbochargers >> 1.4L Turbo Engine (Service Information) 500L >> Manifolds >> Manifold, Intake >> Removal >> Removal

Manifold, Intake: Removal: Removal

  1. Perform the fuel pressure release procedure.

    Refer to FUEL DELIVERY, STANDARD PROCEDURE .

  2. Remove the engine cover assembly.
  3. Recover the refrigerant from the refrigerant system.

    Refer to PLUMBING, STANDARD PROCEDURE .

    Fig 1: 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 three bolts (2) and remove the oil separator housing (4) from the cylinder head cover.
    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 2: PCM Electrical Connectors
    GC0152393Courtesy of CHRYSLER GROUP, LLC
  7. Disconnect and remove the battery.

    Refer to BATTERY, REMOVAL .

  8. Unlock and disconnect the Powertrain Control Module (PCM) harness connectors (1 and 2).
    Fig 3: Battery Tray, Connectors, Retainers, Nut & Bolts
    GC0152563Courtesy of CHRYSLER GROUP, LLC
  9. Disengage two engine wire harness retainers (4) from the battery tray (3).
  10. Disengage the engine wire harness connector (2) from the battery tray (3) and reposition the wire harness.
  11. Remove the nut (5) and two bolts (1) securing battery tray.
  12. Remove the battery tray with the PCM (2) attached.
    Fig 4: EVAP Purge Hose, ETC Harness Connector, Retaining Clip & Clamp
    GC0156027Courtesy of CHRYSLER GROUP, LLC
  13. Unlock and disconnect the harness connector (1) from the Electronic Throttle Control (ETC).
  14. Disconnect the EVAP purge hose (4) from the retaining clip (3).
  15. Loosen the clamp (2) securing the charge air cooler outlet hose to throttle body.
    Fig 5: Oil Separator Housing Bracket & Fasteners
    GC0152568Courtesy of CHRYSLER GROUP, LLC
  16. Remove two bolts (2), one nut (3) and reposition the oil separator housing bracket (1).
    Fig 6: EVAP Purge Hose, Charge Air Cooler Outlet Hose, Retaining Clip, Bolt & Wire Harness Connector
    GC0155526Courtesy of CHRYSLER GROUP, LLC
  17. Disengage the EVAP purge hose (4) from the retaining clip (2) and remove the hose from the charge air cooler outlet hose (5).
  18. Disconnect the boost pressure sensor wire harness connector (1).
  19. Remove the bolts (3) from the charge air cooler outlet hose (5).
  20. Disconnect the charge air cooler outlet hose (5) from the charge air outlet manifold and remove the hose from the vehicle.
    Fig 7: Fuel Purge Hose & Hose Retainer
    GC0156457Courtesy of CHRYSLER GROUP, LLC
  21. Open hose retainer (2) and disconnect the fuel vapor purge hose.
  22. Disconnect the fuel line (1) from the fuel rail.

    Refer to FITTING, QUICK CONNECT, STANDARD PROCEDURE .

    Fig 8: Vacuum Pump & Bolts
    GC0152461Courtesy 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.

  23. Disconnect the vacuum line from the vacuum pump (1).
    Fig 9: IAT/MAP Sensor Harness Connector
    GC0155684Courtesy of CHRYSLER GROUP, LLC
  24. Unlock and disconnect the IAT/MAP sensor harness connector (1).
    Fig 10: Fuel Injector Wire Harness Connector
    GC0156042Courtesy of CHRYSLER GROUP, LLC
  25. Unlock and disconnect the fuel injector wire harness connector (1).
    Fig 11: Purge Flow Control Solenoid & Bracket
    GC0156078Courtesy of CHRYSLER GROUP, LLC
  26. Disengage and reposition the purge flow control solenoid (1) from the bracket (4).
    Fig 12: Support Brackets, Bolts, Retainers & Nuts
    GC0155583Courtesy of CHRYSLER GROUP, LLC
  27. Remove two nuts (1), bolt (7), and the bracket (2).
  28. Disengage the retainers (5) from the support bracket (4).
  29. Remove the nut (3), bolt (6), and the support bracket (4).
  30. Raise and support the vehicle.

    Refer to HOISTING, STANDARD PROCEDURE .

    Fig 13: Lower Air Dam/Belly Pan
    GC0082359Courtesy of CHRYSLER GROUP, LLC
  31. Remove the belly pan.

    Refer to BELLY PAN, REMOVAL .

  32. Drain the cooling system.

    Refer to STANDARD PROCEDURE .

    Fig 14: Tunnel Support Brace & Bolts
    GC0152449Courtesy of CHRYSLER GROUP, LLC
  33. Remove four bolts (1) and the tunnel support brace (2).
  34. Remove both front wheels and tires.

    Refer to REMOVAL .

    Fig 15: Right Vertical Brace, Frame Splash Shield & Fasteners
    GC0153366Courtesy of CHRYSLER GROUP, LLC
  35. Remove two bolts (4) and the right vertical brace (5).
  36. Remove two screws (2) from the front wheelhouse splash shield.
  37. Remove three screws (1) and the frame splash shield (3).
    Fig 16: Drive Belt Tensioners & Assembly With Drive Belt Routing
    GC0152365Courtesy of CHRYSLER GROUP, LLC
  38. Remove the accessory drive belt (4).

    Refer to BELT, SERPENTINE, REMOVAL .

  39. Lower the vehicle.
    Fig 17: A/C Compressor & Fasteners
    GC0152459Courtesy of CHRYSLER GROUP, LLC
  40. Remove the A/C compressor (1).

    Refer to COMPRESSOR, A/C, REMOVAL .

    Fig 18: A/C Suction Line, Nut, Heater Core Outlet Hose & Inlet Hose
    GC0152409Courtesy of CHRYSLER GROUP, LLC
  41. Disconnect the heater core outlet hose (3) and inlet hose (4) from the heater core.
    Fig 19: Wire Harness Retainers
    GC0152434Courtesy of CHRYSLER GROUP, LLC
  42. Raise and support the vehicle.

    Refer to HOISTING, STANDARD PROCEDURE .

  43. Open the two wire harness retainers (1) and reposition the wire harness.
  44. Lower the vehicle.
    Fig 20: Hose Retainer & Bolt
    GC0156303Courtesy of CHRYSLER GROUP, LLC
  45. Remove the bolt (2) securing the hose retainer (1) to the intake manifold.
    Fig 21: Intake Manifold Flange Bolts
    GC0152435Courtesy of CHRYSLER GROUP, LLC
  46. Remove the seven intake manifold flange bolts (1) and remove the intake manifold from vehicle.
    Fig 22: Intake Manifold Seals
    GC0156373Courtesy of CHRYSLER GROUP, LLC
  47. Remove and discard the four intake manifold seals (1).
  48. Cover the open intake ports to prevent debris from entering the engine.
  49. If required, remove the following components from the intake manifold:
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