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1.4L Turbo Engine (Service Information) - 500L: Installation

GC0176841Courtesy 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, REAR, INSTALLATION .
  5. Remove the engine lift and the leveling tool (1).
  6. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
  7. Install the rear engine mount. Refer to INSULATOR, ENGINE MOUNT, REAR, INSTALLATION .
  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 TECHNICAL SPECIFICATIONS .
  11. Tighten the exhaust pipe bracket bolt. Refer to TECHNICAL SPECIFICATIONS .
    GC0155869Courtesy of CHRYSLER GROUP, LLC
  12. Connect the wire harness connectors to the upstream (1) and downstream (2) oxygen sensors.
  13. Engage the oxygen sensor wire harness to the retainer (3).
  14. Install the left and right axle shafts. Refer to INSTALLATION .
    GC0159022Courtesy of CHRYSLER GROUP, LLC
  15. Lower the vehicle.
  16. Connect the fuel and vapor lines (1) to the fittings.
    GC0158852Courtesy of CHRYSLER GROUP, LLC
  17. Release the line retainer. Insert the fresh air, fuel liquid and vapor lines into the retainer (1). Lock the retainer.
    GC0158889Courtesy of CHRYSLER GROUP, LLC
  18. Position the Front End Module (FEM) to the frame rails.
  19. Insert the three lower frame rail bolts (2). Repeat both sides.
  20. Install the air-conditioning lines with new seals to the expansion valve. Install the nut and tighten to 20 N.m (15 ft. lbs.).
  21. Connect the heater core inlet hose and outlet hose to the heater core fittings.
    GC0155791Courtesy of CHRYSLER GROUP, LLC
  22. Install the charge air cooler outlet hose (2). Tighten the bolt (3) to 9 N.m (80 in. lbs.).
  23. Tighten the clamp (1) securing the charge air cooler outlet hose to the pipe.
  24. Connect the boost pressure sensor wire harness connector.
  25. Install the afterrun pump hoses and secure the clamps in position.
    GC0168972Courtesy of CHRYSLER GROUP, LLC
  26. Install the gearshift cable (2) to the bracket (1).
  27. Connect the gearshift cable (2) to the transmission manual valve lever (3).
  28. Connect the wire harness connector (4) to the Transmission Control Module (TCM).
  29. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
    GC0158908Courtesy of CHRYSLER GROUP, LLC
  30. Install the cooling module (5) to the FEM. Tighten the mount bolts (3).
  31. Connect the cooling fan motor harness connector (6).
  32. Connect the cooling fan resistor harness connector (1).
    GC0158708Courtesy of CHRYSLER GROUP, LLC
  33. Install the air dam (3) by pinching the expanders (1) to secure into the core.

  34. Install and tighten the mount bolts (2).

    GC0153091Courtesy of CHRYSLER GROUP, LLC
  35. Install the bumper reinforcement (1).
    GC0158638Courtesy of CHRYSLER GROUP, LLC
  36. 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.).
  37. Install the lower radiator hose to the engine.
  38. Install the cross-under pipe.
  39. Engage the oxygen sensor wire harness to the retainer.
  40. Connect the wire harness connectors to the upstream and downstream oxygen sensors.
    GC0168960Courtesy of CHRYSLER GROUP, LLC
  41. 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.
  42. Install both front inner wheel well splash shields. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE INSTALLATION .
  43. Install both front tire and wheel assemblies. Refer to INSTALLATION .
  44. Install the belly pan. Refer to BELLY PAN, INSTALLATION .
  45. Lower the vehicle.
  46. Position the battery tray and PCM in the vehicle. Route the wire harness and close the wire harness retainers (3).
  47. Install the ground strap (4) with nut (1) tightened to 5 N.m (44 in. lbs.).
  48. Position the wire harness into wire harness retainers (3) and close retainers.
  49. Install the battery tray. Refer to TRAY, BATTERY, INSTALLATION .
  50. Install the vacuum pump. Refer to PUMP, VACUUM, REMOVAL .
  51. Connect the Powertrain Control Module (PCM) harness connectors.
  52. Install the upper radiator hose to the engine.
  53. Lower the vehicle.
    GC0176840Courtesy of CHRYSLER GROUP, LLC
  54. Install the oil vapor separator to the cylinder head cover with new O-ring and tighten the bolts (1) to 13 N.m (115 in. lbs.).
    GC0176822Courtesy of CHRYSLER GROUP, LLC
  55. Install and tighten the engine oil vapor pipe middle bracket bolt (1).
    GC0176834Courtesy of CHRYSLER GROUP, LLC
  56. Connect the oil vapor recovery pipe and tighten the clamp (1).
    GC0176848Courtesy of CHRYSLER GROUP, LLC
  57. Connect the idle oil vapor delivery pipe and tighten the clamp (1).
  58. Install the air cleaner body. Refer to BODY, AIR CLEANER, INSTALLATION .
  59. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to OIL, STANDARD PROCEDURE .
  60. Fill the cooling system. Refer to STANDARD PROCEDURE .
  61. Install the battery tray and battery. Refer to TRAY, BATTERY, INSTALLATION .
  62. Evacuate and charge the refrigerant system. Refer to PLUMBING, STANDARD PROCEDURE .
  63. 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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