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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) >> Turbocharger System >> Turbocharger >> Installation >> Installation

Turbocharger System: Turbocharger: Installation: Installation

WARNING: This page is about a different variant/trim than selected.
CAUTION:

The oil supply and return lines MUST be replaced whenever the lines are loosened or removed.

GC0153796Courtesy of CHRYSLER GROUP, LLC
  1. With the manifold removed, invert the manifold and turbocharger.
  2. Install a new  gasket onto the manifold/turbocharger mating surface.
  3. Set the manifold onto the turbocharger studs and install four new  nuts (1) by hand.
  4. Tighten the four nuts to 24 N.m (18 ft. lbs.).
  5. After the nuts are tightened to 24 N.m (18 ft. lbs.) once, repeat the step to be sure that all nuts are at the proper torque.
    NOTE:

    Replace any stud that loosens during removal. If a stud is to be replaced, tighten the new stud to 11 N.m (97 in. lbs.). Age of the vehicle and environment impact how many of the studs come out. Any that stay in the head also need to be checked for the 11 N-m (97 in. lbs.).

    GC0162357Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    When screwing the studs into the head, install them dry. Do not apply any lubricants, adhesives, sealants or the like to the threads. The new studs have a locking adhesive impregnated into the threads.

  6. Install new manifold studs. Tighten the studs to 11 N.m (97 in. lbs.).
  7. Install a new  manifold gasket/shield assembly (1).
    GC0153801Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The turbocharger has been removed for clarity.

  8. Set the manifold and turbocharger assembly onto the cylinder head studs.
  9. Install the nine exhaust manifold washers and new  nuts (1) finger tight.
  10. Tighten the exhaust manifold nuts in the sequence shown in illustration, following this three step torque plus angle method. The torque sequence must be used for each step. Tighten according to the following torque values:
    • Step 1: All to 15 N.m (133 in. lbs.)
    • Step 2: 1 to 5 only  again to 15 N.m (133 in. lbs.)
    • Step 3: All + 30° Turn Do not use a torque wrench for this step. 
    GC0162362Courtesy of CHRYSLER GROUP, LLC
  11. Position the exhaust manifold shield (2) and install the bolts and new  nuts.
  12. Tighten the shield bolts to 9 N.m (80 in. lbs.).
    GC0162372Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The oil supply and return tubes must be replaced during assembly or ANY TIME the fittings are loosened. 

  13. Install a new gasket on the oil return tube flange (1) and fold the retaining tabs.
    GC0162366Courtesy of CHRYSLER GROUP, LLC
  14. Install a new O-ring (1) on the oil return tube.
    GC0162352Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Banjo bolts and banjo bolt gaskets must be replaced during assembly. 

  15. Install the new  turbocharger oil return tube (3) with new gaskets. Tighten the bolts (1, 2) to 9 N.m (80 in. lbs.).
  16. Install the new  banjo bolt (3) with new  banjo bolt washers and tighten to 38 N.m (28 ft. lbs.).
    GC0162365Courtesy of CHRYSLER GROUP, LLC
  17. Install the new  turbocharger oil supply tube (1) to the turbocharger with new  banjo bolt washers and a new  banjo bolt tighten to 30 N.m (22 ft. lbs.).
    GC0162361Courtesy of CHRYSLER GROUP, LLC
  18. Install the new  turbocharger oil supply tube (1) to the oil filter housing with new  banjo bolt washers and a new  banjo bolt tightened to 24 N.m (18 ft. lbs.).
    GC0162355Courtesy of CHRYSLER GROUP, LLC
  19. Install the coolant supply tube to the turbocharger with new  banjo bolt washers and a new  banjo bolt tighten to 38 N.m (28 ft. lbs.).
    GC0162354Courtesy of CHRYSLER GROUP, LLC
  20. Install the coolant return tube to the turbocharger with new  banjo bolt washers and a new  banjo bolt tighten to 38 N.m (28 ft. lbs.).
    GC0162368Courtesy of CHRYSLER GROUP, LLC
  21. Install the coolant return tube to the coolant return pipe with a new gasket. Tighten the bolt (3) to 14 N.m (124 in. lbs.).
  22. Connect the wastegate actuator hose (2) to the turbocharger.
  23. If removed, install the surge valve and tighten the bolts to 9 N.m (80 in. lbs.).
  24. Connect and lock the turbocharger surge valve wire harness connector (1).
    GC0162356Courtesy of CHRYSLER GROUP, LLC
  25. Install the engine oil cooler heat shields (1b) and tighten the screws (1a) to 3 N.m (26 in. lbs.).
    GC0153789Courtesy of CHRYSLER GROUP, LLC
  26. Install the new  converter to turbo seal ring (1).
    GC0153788Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    Band clamps should never be tightened such that the two sides of the clamps are bottomed out against the hourglass shaped center block. Once this occurs, the clamp has lost clamping force and must be replaced.

  27. Install the catalytic converter assembly (3).
  28. Install the catalytic converter v-clamp (2) at the turbocharger (1) and tighten the clamp to 8 N.m (71in. lb).
    GC0153601Courtesy of CHRYSLER GROUP, LLC
  29. Install the catalytic converter lower support bracket (2) and tighten the bracket bolts (3) to 56 N.m (41 ft. lbs.).
    GC0170951Courtesy of CHRYSLER GROUP, LLC
  30. Install a new converter to pipe gasket (3).
  31. Install the front exhaust pipe to the catalytic converter and tighten the 2 nuts (2) to 28 N.m (21 ft. lbs.).
    GC0153120Courtesy of CHRYSLER GROUP, LLC
  32. Install the front exhaust pipe support bolt (2) and tighten to 56 N.m (41 ft. lbs.).
  33. Install the exhaust flange nuts (1) and tighten to 69 N.m (51 ft. lbs.).
    GC0155869Courtesy of CHRYSLER GROUP, LLC
  34. Connect the upstream oxygen sensor connector (1) and downstream oxygen sensor connector (2) and engage the wire harness to the retainer (3).
    GC0153600Courtesy of CHRYSLER GROUP, LLC
  35. Install the lower catalytic converter heat shield (3) with two new  nuts (2) and one bolt (1). Tighten the nuts and bolt to 9 N.m (80 in. lbs.).
  36. Install the Charge Air Cooler (CAC) supply hose (5) to the turbocharger outlet and tighten the clamp.
  37. Install the bolt (4) securing the Charge Air Cooler (CAC) supply hose (5) to the lower catalytic converter heat shield (3) and tighten to 9 N.m (80 in. lbs.).
    GC0153792Courtesy of CHRYSLER GROUP, LLC
  38. Install the upper catalytic converter heat shield with three bolts (1) and two new  nuts (2). Tighten the nuts and bolts to 9 N.m (80 in. lbs.).Care must be taken when tightening the shield bolts. If torque value is not correct, noise will occur. 
    GC0153805Courtesy of CHRYSLER GROUP, LLC
  39. Install the turbocharger bracket (2), bolts (1) and new  nut (3).
  40. Tighten the bolts and nut to 25 N.m (18 ft. lbs.).
    GC0153119Courtesy of CHRYSLER GROUP, LLC
  41. Install the front cooling module assembly (4) with four bolts (1), eight bolts and washers (2) and eight bolts and washers (3). Tighten the eight bolts (2) to 45 N.m (33 ft. lb.). Tighten the four bolts (1) to 24 N.m (18 ft. lb.). Tighten the eight bolts (3) to 45 N.m (33 ft. lb.).
    GC0153790Courtesy of CHRYSLER GROUP, LLC
  42. Connect the throttle body inlet hose (1) and turbocharger outlet hose (2) at the lower quick disconnects located behind the cooling fan (3).
    GC0103128Courtesy of CHRYSLER GROUP, LLC
  43. Engage the wire harness retainer (1) to the bottom of the bumper reinforcement.
    GC0103127Courtesy of CHRYSLER GROUP, LLC
  44. Connect the wire harness connector (1) to the ambient air temperature sensor.
    GC0153791Courtesy of CHRYSLER GROUP, LLC
  45. Connect the wire harness connector (1) to the horn (2).
    GC0153793Courtesy of CHRYSLER GROUP, LLC
  46. Connect the wire harness connector (2) to the right and left front impact sensors (1).
    GC0084616Courtesy of CHRYSLER GROUP, LLC
  47. Press down the latch release (3) and install the hood latch cable (2) to the latch.
    GC0152540Courtesy of CHRYSLER GROUP, LLC
  48. 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
  49. Connect the cooling fan electrical connector (3).
  50. Install the upper and lower radiator hoses and clamps. Tighten the clamps.
    GC0152401Courtesy of CHRYSLER GROUP, LLC
  51. Connect the electrical connector to the cooling fan resistor (1).
    GC0153009Courtesy of CHRYSLER GROUP, LLC
  52. Install the right and left headlamp units (2).
  53. Install the front fascia Refer to FASCIA, FRONT, INSTALLATION .
  54. Install the belly pan

    Refer to BELLY PAN, INSTALLATION .

  55. 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  .

  56. Install the air cleaner body

    Refer to BODY, AIR CLEANER, INSTALLATION .

  57. Fill the cooling system

    Refer to STANDARD PROCEDURE .

  58. Connect the negative battery cable.
  59. Evacuate and charge the refrigerant system

    Refer to HEATING AND AIR CONDITIONING, STANDARD PROCEDURE .

  60. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level

    Refer to STANDARD PROCEDURE .

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