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Home >> Fiat >> 2017 >> 500 Lounge, Standard Trans >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 3 (1.4L 16-Valve Turbo Engine (Service Information) - 500) >> Installation >> With Automatic Transmission

With Automatic Transmission

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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, REAR, 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).
    GC0152654Courtesy of CHRYSLER GROUP, LLC
  6. Remove the

    (special tool #10299, Bracket, Engine Lifting)

    GC0154236Courtesy of CHRYSLER GROUP, LLC

    (1).

    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.

    CAUTION:

    The vacuum hose and the pressurized coolant bottle return hose have the same quick-connect fitting end. Verify that the hoses are correctly installed. Failure to properly install the hoses can result in engine damage.

  7. Install the vacuum pump (1). Refer to PUMP, VACUUM, REMOVAL .
    GC0156457Courtesy of CHRYSLER GROUP, LLC
  8. Connect the fuel line (1) to the fuel rail.
  9. Connect the fuel vapor purge hose (2) to the intake manifold and close the hose retainer (3).
    GC0152409Courtesy of CHRYSLER GROUP, LLC
  10. Install the A/C suction line (1) with a new O-ring seal to the A/C expansion valve. Install the nut (2) and tighten to 20 N.m (15 ft. lbs.).
  11. Connect the heater core inlet hose (4) and outlet hose (3) to the heater core.
    GC0168972Courtesy of CHRYSLER GROUP, LLC
  12. Install the gearshift cable (2) to the bracket (1).
  13. Connect the gearshift cable (2) to the transmission manual valve lever (3).
  14. Connect the wire harness connector (4) to the Transmission Control Module (TCM).
    GC0168960Courtesy of CHRYSLER GROUP, LLC
  15. Install the ground cable (1) to the transmission case. Tighten the bolt (2) to 9 N.m (80 in. lbs.).
    GC0155526Courtesy of CHRYSLER GROUP, LLC
  16. Install the charge air cooler outlet hose (5) to the vehicle. Tighten bolt (3) to 9 N.m (80 in. lbs.).
  17. Tighten the clamp securing the charge air cooler outlet hose to the throttle body.
  18. Install the EVAP purge hose (4) to the charge air cooler outlet hose (5) and engage the hose to the retaining clip (2).
  19. Connect the boost pressure sensor wire harness connector (1).
    GC0156417Courtesy of CHRYSLER GROUP, LLC
  20. Install the pressurized coolant bottle (1). Tighten the two bolts (5) to 8 N.m (70 in. lbs.).
  21. Install the coolant hose (3) to the pressurized coolant bottle (1).
  22. Connect the after-run pump coolant hoses (2 and 4).
    GC0153014Courtesy of CHRYSLER GROUP, LLC
  23. Install the windshield washer fluid reservoir

    Refer to RESERVOIR, WINDSHIELD WASHER, INSTALLATION .

    GC0152406Courtesy of CHRYSLER GROUP, LLC
  24. Raise and support the vehicle. Refer to HOISTING .
  25. Install the rear engine mount. Refer to INSULATOR, ENGINE MOUNT, REAR, INSTALLATION .
    GC0152930Courtesy of CHRYSLER GROUP, LLC
  26. Install the intermediate shaft and both axle shafts

    Refer to INSTALLATION .

    GC0155869Courtesy of CHRYSLER GROUP, LLC
  27. Engage the oxygen sensor wire harness to the retainer (3).
  28. Connect the wire harness connectors to the upstream (1) and downstream (2) oxygen sensors.
    GC0153601Courtesy of CHRYSLER GROUP, LLC
  29. Position the exhaust pipe to the catalytic converter outlet. Install a new gasket and nuts.
  30. Install the pipe bracket and bolt.
  31. Tighten the flange bolts to the proper specification. Refer to TORQUE SPECIFICATIONS  .
  32. Tighten the exhaust pipe bracket bolt to the proper specification. Refer to TORQUE SPECIFICATIONS  .
    GC0157930Courtesy of CHRYSLER GROUP, LLC
  33. Lower the vehicle.
  34. Install the front cooling module assembly (3) with the lower frame members attached using four bolts (1) and eight bolts and washers (2). Tighten the eight bolts (2) to 45 N.m (33 ft. lb.) and tighten the four bolts (1) to 24 N.m (18 ft. lb.).
    GC0153790Courtesy of CHRYSLER GROUP, LLC
  35. Connect the throttle body inlet hose (1) and turbocharger outlet hose (2) at the lower quick connects located behind the cooling fan (3).
    GC0103128Courtesy of CHRYSLER GROUP, LLC
  36. Engage the wire harness retainer (1) to the bottom of the bumper reinforcement.
    GC0103127Courtesy of CHRYSLER GROUP, LLC
  37. Connect the wire harness connector (1) to the ambient air temperature sensor.
    GC0153791Courtesy of CHRYSLER GROUP, LLC
  38. Connect the wire harness connector (1) to the horn (2).
    GC0153793Courtesy of CHRYSLER GROUP, LLC
  39. Connect the wire harness connector (2) to the right and left front impact sensors (1)

    Refer to SENSOR, IMPACT, INSTALLATION .

    GC0084616Courtesy of CHRYSLER GROUP, LLC
  40. Press down the latch release (3) and install the hood latch cable (2) to the latch.
    GC0152540Courtesy of CHRYSLER GROUP, LLC
  41. Engage the A/C liquid line (1) to the A/C discharge line (2) and connect the lines to the A/C condenser tapping block (3) using new dual plain seals lubricated with clean refrigerant oil. Install the retaining bolt (4) and tighten to 14 N.m (10 ft. lbs.).
    GC0152367Courtesy of CHRYSLER GROUP, LLC
  42. Connect the lower coolant hose to the radiator.
  43. Connect the cooling fan wire harness connector (3).
    GC0152401Courtesy of CHRYSLER GROUP, LLC
  44. Connect the upper coolant hose to the radiator.
  45. Connect the wire harness connector to the cooling fan resistor (1).
    GC0153009Courtesy of CHRYSLER GROUP, LLC
  46. Install the right and left headlamp units (2)

    Refer to UNIT, HEADLAMP, INSTALLATION .

    GC0153127Courtesy of CHRYSLER GROUP, LLC
  47. Install the front fascia (1)

    Refer to FASCIA, FRONT, INSTALLATION .

    GC0153366Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Right vertical brace shown, left vertical brace similar.

  48. Install the frame splash shield (3) with three screws (1).
  49. Install the right and left vertical brace (5) with two bolts (4) tightened to 45 N.m (33 ft. lbs.).
    GC0152449Courtesy of CHRYSLER GROUP, LLC
  50. Install both front inner wheel well splash shields

    Refer to SHIELD, SPLASH, FRONT WHEELHOUSE INSTALLATION .

  51. Install both front tire and wheel assemblies

    Refer to INSTALLATION .

  52. Install the tunnel support brace (2). Tighten bolts (1) to 100 N.m (74 ft. lb.).
    GC0082359Courtesy of CHRYSLER GROUP, LLC
  53. Install the belly pan. Refer to BELLY PAN, INSTALLATION .
    GC0152563Courtesy of CHRYSLER GROUP, LLC
  54. Lower the vehicle.
  55. Install the battery tray (3) and PCM in the vehicle. Route the wire harness and close the wire harness retainers. Refer to TRAY, BATTERY, INSTALLATION .
    GC0152393Courtesy of CHRYSLER GROUP, LLC
  56. Engage and lock the Powertrain Control Module (PCM) harness connectors.
  57. Install the upper radiator hose to the engine.
  58. Install the lower radiator hose to the engine.
  59. Fill the transmission with the proper fluid to the correct level.
    GC0155887Courtesy of CHRYSLER GROUP, LLC
  60. Lower the vehicle.
  61. Install the oil separator housing (4) to the cylinder head cover with three bolts (2) tightened to 13 N.m (115 in. lbs.).
  62. Connect the vent hose (3) to the cylinder head cover.
  63. Connect the PCV hose (1) to the intake manifold.
    GC0153787Courtesy of CHRYSLER GROUP, LLC
  64. Install the air cleaner body (1). Refer to BODY, AIR CLEANER, INSTALLATION .
  65. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to STANDARD PROCEDURE - ENGINE OIL AND FILTER CHANGE  .
  66. Fill the cooling system. Refer to STANDARD PROCEDURE .
  67. Install and connect the battery. Refer to BATTERY, INSTALLATION .
  68. Evacuate and charge the refrigerant system. Refer to STANDARD PROCEDURE - ENGINE OIL AND FILTER CHANGE  .
  69. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to STANDARD PROCEDURE .
  70. The Clear Misfire TLC Miscellaneous Function 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 1.4L - INTERMITTENT CONDITION, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE - 500 .
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