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Home >> Fiat >> 2017 >> 500L Pop >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> 1.4L Turbo Engine (Service Information) - 500L >> Manifolds >> Manifold, Intake >> Removal

Manifold, Intake: Removal

  1. Perform the fuel pressure release procedure. Refer to FUEL SYSTEM PRESSURE RELEASE .
  2. Remove the engine cover assembly.
  3. Recover the refrigerant from the refrigerant system. Refer to PLUMBING, STANDARD PROCEDURE .
  4. Disconnect the PCV hose from the intake manifold.
  5. Disconnect the vent hose from the cylinder head cover.
  6. Remove three bolts and remove the oil separator housing from the cylinder head cover.
    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).
    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.
    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.
    GC0152568Courtesy of CHRYSLER GROUP, LLC
  16. Remove two bolts (2), one nut (3) and reposition the oil separator housing bracket (1).
    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.
    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.
    GC0152461Courtesy of CHRYSLER GROUP, LLC
  23. Disconnect the vacuum line from the vacuum pump (1).
    GC0155684Courtesy of CHRYSLER GROUP, LLC
  24. Unlock and disconnect the IAT/MAP sensor harness connector (1).
    GC0156078Courtesy of CHRYSLER GROUP, LLC
  25. Disengage and reposition the purge flow control solenoid (1) from the bracket (4).
    GC0155583Courtesy of CHRYSLER GROUP, LLC
  26. Remove two nuts (1), bolt (7), and the bracket (2).
  27. Disengage the retainers (5) from the support bracket (4).
  28. Remove the nut (3), bolt (6), and the support bracket (4).
  29. Remove the belly pan. Refer to BELLY PAN, REMOVAL .
  30. Drain the cooling system. Refer to STANDARD PROCEDURE .
    GC0152449Courtesy of CHRYSLER GROUP, LLC
  31. Remove four bolts (1) and the tunnel support brace (2).
    GC0153366Courtesy of CHRYSLER GROUP, LLC
  32. Remove both front wheels and tires.
  33. Remove two bolts (4) and the right vertical brace (5).
  34. Remove two screws (2) from the front wheelhouse splash shield.
  35. Remove three screws (1) and the frame splash shield (3).
  36. Remove the accessory drive belt. Refer to BELT, SERPENTINE, REMOVAL .
  37. Remove the A/C compressor. Refer to COMPRESSOR, A/C, REMOVAL .
    GC0152409Courtesy of CHRYSLER GROUP, LLC
  38. Disconnect the heater core outlet hose (3) and inlet hose (4) from the heater core.
    GC0152434Courtesy of CHRYSLER GROUP, LLC
  39. Open the two wire harness retainers (1) and reposition the wire harness.
    GC0156303Courtesy of CHRYSLER GROUP, LLC
  40. Remove the bolt (2) securing the hose retainer (1) to the intake manifold.
    GC0152435Courtesy of CHRYSLER GROUP, LLC
  41. Remove the seven intake manifold flange bolts (1) and remove the intake manifold from the vehicle.
    GC0156373Courtesy of CHRYSLER GROUP, LLC
  42. Remove and discard the four intake manifold seals (1).
  43. Cover the open intake ports to prevent debris from entering the engine.
  44. If required, remove the following components from the intake manifold:
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