ENGINE Exhaust System FIAT 500

2012 Fiat 500 Pop
2012 ENGINE Exhaust System - Fiat 500
2012 ENGINE
Exhaust System - Fiat 500
DESCRIPTION
DESCRIPTION
Fig. 1: Resonator/Pipe Assembly, Muffler/Pipe Assembly & Support Isolators

Courtesy of CHRYSLER GROUP, LLC
The exhaust system on the 1.4L engine models consists of a front mounted catalytic converter/maniverter,
resonator/pipe assembly (3), muffler/pipe assembly (2), band clamp, and support isolators (1). The upstream
oxygen sensor is located in the exhaust manifold. The downstream oxygen sensor is located in the catalytic
converter.
Resonators, mufflers, and exhaust pipes are tuned to each powertrain combination.
DIAGNOSIS AND TESTING

EXHAUST SYSTEM
EXHAUST SYSTEM DIAGNOSIS CHART

CONDITION POSSIBLE CAUSE CORRECTION
EXCESSIVE EXHAUST NOISE 1. Leaks at pipe joints. 1. Tighten clamps/bolts at leaking
OR LEAKING EXHAUST joints.
GASES 2. Rusted or blown out muffler. 2. Replace muffler. Inspect
exhaust system.
3. Broken or rusted out exhaust 3. Replace exhaust pipe.
pipe.
MANUAL
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2012 Fiat 500 Pop
4. Exhaust pipe leaking at 4. Tighten/replace flange attaching

manifold flange. nuts/bolts.
5. Exhaust manifold cracked or 5. Replace exhaust manifold.
broken.
6. Leak between exhaust manifold 6. Tighten exhaust manifold to
and cylinder head. cylinder head bolts.
7. Catalytic converter rusted or 7. Replace catalytic converter
blown out. assembly and gasket.
8. Restriction in exhaust system. 8. Remove restriction, if possible.
Replace restricted part if
necessary.
CAUTION:
When servicing and replacing exhaust system components, disconnect the oxygen sensor
connector(s). Allowing the exhaust to hang by the oxygen sensor wires will damage the harness
and/or sensor.
LEAK TESTING
WARNING: The normal operating temperature of the exhaust system is very high.
Therefore, never work around or attempt to service any part of the
exhaust system until it is cooled. Special care should be taken when
working near the catalytic converter. The temperature of the converter
rises to a high level after a short period of engine operation time.
1. Raise and support vehicle.
CAUTION: The air pressure must not exceed 4 psi, otherwise engine damage
can occur.
2. Connect Tool (special tool #8404-ECT, Exhaust Cone, Truck), Exhaust Cone to Air Pressure Regulator
(with hose) W-18-MIL-1146AS.
3. Attach shop air to the air pressure regulator.
4. Adjust the air pressure regulator to 4 psi.
5. Insert Tool (special tool #8404-EC, Exhaust Cone) or (special tool #8404-ECT, Exhaust Cone, Truck),
Exhaust Cone into the vehicle tail pipe.
6. If the vehicle is equipped with dual exhaust, use Tool (special tool #8404-EC, Exhaust Cone) or (special
tool #8404-ECT, Exhaust Cone, Truck), Exhaust Cone with equipped attached plug. Plug one side of the
dual exhaust pipe. Pressurize the other as described.
7. Apply a mixture of MOPAR® Air Leak Detector to the following areas:
- All welded joints from 6 inches rearward of the downstream O2 sensor forward.
- O2 sensor seal points.
- O2 sensor boss welds.
MANUAL
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2012 Fiat 500 Pop
- Flange/joint connection(s).
- Exhaust manifold to cylinder head connection(s).
- EGR solenoid gasket base and tube seal points (if equipped).
8. Watch for the Air Detector to bubble.
9. Use the following definitions to help determine if system or component repair/replacement is necessary:
Type 1 Leak is defined as a leak where very small foam like bubbles 1mm (.039 in.) or less appear. Any
Type 1 or greater leaks found in welded joints, O2 sensor seal points or O2 sensor boss welds must be
repaired or the component must be replaced.
Type 2 Leak is defined as a leak where larger bubbles 8mm (.32 in.) or greater appear. Any Type 2 or
greater leaks found in flange or joint connections, exhaust manifold to cylinder head connections, or EGR
gasket and tube seal points must be repaired or the components must be replaced.
Repair
required
if results
Leak Location at 4 psi
reveal
bubble
size:
Type 1 -
1 mm
Welded joints (.039 in.)
or
greater
Type 1 -
1 mm
O2 Sensor seal points (.039 in.)
or
greater
Type 1 -
1 mm
O2 Sensor boss welds (.039 in.)
or
greater
Type 2 -
8 mm
Flange/joint connections (.32 in.)
or
greater
Type 2 -
8 mm
Exhaust Manifold to cylinder head connections (.32in.)
or
greater
MANUAL
2012 Fiat 500 Pop
Type 2 -
8 mm
EGR gasket and tube seal points (.32 in.)
or
greater
If a leak is found that matches the above definition, repair or replace the component as necessary.
Once the repair is complete, repeat the procedure to verify that all leaks have been repaired.
SPECIFICATIONS
SPECIFICATIONS
DESCRIPTION N.m Ft. Lbs. In. Lbs.

Band Clamp Nut 55 40 -
Nuts-Exhaust Flange 25 18 221
SPECIAL TOOLS
SPECIAL TOOLS
8404-EC - Exhaust Cone

8404-ECT - Exhaust Cone, Truck
(Originally Shipped In Kit Number(s) 8404-ECT.)
CONVERTER, CATALYTIC
DESCRIPTION
DESCRIPTION
1. The catalytic converter is mounted between the turbocharger and the front exhaust pipe. The upstream O2
sensor boss is welded onto the inlet pipe.
2. The converter is mated to the turbocharger by way of a band clamp. The outlet pipe of the converter is
secured by a two piece bracket and is attached to the front exhaust pipe by way of a flange. Both ends
require gaskets.
DESCRIPTION
The gas engine exhaust system components consist of a maniverter, intermediate pipe, mufflers, and support
isolators.
The catalytic converter is part of the exhaust manifold, called a maniverter.
MANUAL
2012 Fiat 500 Pop
For removal of the maniverter. Refer to MANIFOLD, EXHAUST, REMOVAL or MANIFOLD,

EXHAUST, REMOVAL or MANIFOLD, EXHAUST, REMOVAL .
REMOVAL
REMOVAL
1. Disconnect and isolate the negative battery cable.
Fig. 2: Air Cleaner Assembly, Intake Hose, Fittings & Clamp

2. Disconnect the two vacuum fittings (4), loosen the clamp (3) at the air to turbocharger inlet tube.
3. Disconnect he fresh air intake hose (2).
4. Remove the air cleaner assembly (1).
MANUAL
2012 Fiat 500 Pop
Fig. 3: Upper Heat Shield Bolts & Nuts

5. Remove the upper heat shield bolts (1) and nuts (2).
Fig. 4: Charge Air Cooler Supply Hose, Heat Shield, Nuts & Bolts
6. Remove the Charge Air Cooler (CAC) supply hose (5) from the turbocharger.
7. Remove the catalytic converter heat shield (3).
8. Disconnect the upstream and downstream O2 sensor connectors.
Fig. 5: Turbocharger & Catalytic Converter Clamp

MANUAL
2012 Fiat 500 Pop
9. Loosen the catalytic converter clamp (2) at the turbocharger (1).

10. Raise and support vehicle. Refer to HOISTING, STANDARD PROCEDURE .
11. If equipped, remove the belly pan.
Fig. 6: Front Exhaust Pipe Support Bolt & Flange Nuts

12. Remove the front exhaust pipe support bolt (2).

13. Remove the exhaust flange nuts (1).
Fig. 7: Catalytic Converter, Support Mount & Bolts

14. Remove the nuts that secure the cross under pipe to the catalytic converter.
15. Remove the front exhaust pipe and flange gasket.
MANUAL
2012 Fiat 500 Pop
16. Unbolt the 4 converter mount bolts (3).

17. Remove the lower catalytic converter support mount (2).
18. Carefully lower the catalytic converter (1) down and out of the vehicle.
Fig. 8: Catalytic Converter Gasket Ring

19. Remove the catalytic converter gasket ring.
INSTALLATION
INSTALLATION
Fig. 9: Catalytic Converter Gasket Ring

MANUAL
2012 Fiat 500 Pop
1. Install the converter to turbo seal ring (1).
Fig. 10: Turbocharger & Catalytic Converter Clamp

2. Install the catalytic converter assembly (3).

3. Position the exhaust manifold shield and install the 3 bolts.
4. Tighten the shield bolts to 9 N.m (80 in. lbs.).
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.
5. Install the catalytic converter v-clamp (2) at the turbocharger (1).

6. Tighten clamp to 8 N.m (71in. lbs).
7. Connect the O2 sensor connector.
MANUAL
2012 Fiat 500 Pop
Fig. 11: Catalytic Converter, Support Mount & Bolts

8. Install the lower catalytic converter support bracket (2).

9. Install and tighten the bracket bolts (3) to 56 N.m (41 ft. lbs.).
10. Install a new converter to pipe gasket.
11. Install the front exhaust pipe.
12. Install the nuts that secure the cross under pipe to the catalytic converter.
13. Tighten the front exhaust pipe nuts to 56 N.m (41 ft. lbs.).
Fig. 12: Front Exhaust Pipe Support Bolt & Flange Nuts
14. Install the front exhaust pipe support bolt (2). Tighten to 56 N.m (41 ft. lbs.).
MANUAL
2012 Fiat 500 Pop
15. Install the exhaust flange nuts (1). Tighten to 69 N.m (51 ft. lbs.).
Fig. 13: Charge Air Cooler Supply Hose, Heat Shield, Nuts & Bolts
16. Install the Charge Air Cooler (CAC) supply hose (5) to the turbocharger.
17. Install the CAC hose clamp and tighten.
18. Install the catalytic converter heat shield (3).
Fig. 14: Upper Heat Shield Bolts & Nuts

19. Tighten the nuts and bolts to 8 N.m (71 in. lbs.).
20. Connect the upstream and downstream O2 sensor connectors.
MANUAL
2012 Fiat 500 Pop
Fig. 15: Air Cleaner Assembly, Intake Hose, Fittings & Clamp
21. Install the air cleaner assembly (1).

22. Connect he fresh air intake hose (2).
23. Connect the two vacuum fittings (4), tighten the clamp (3) at the air to turbocharger inlet tube.
24. Connect the negative battery cable.
MUFFLER, EXHAUST
REMOVAL
REMOVAL
Fig. 16: Exhaust Pipe, Muffler Pipe & Clamp

MANUAL
2012 Fiat 500 Pop
1. Loosen the clamp (1) at the exhaust pipe (3) and the muffler pipe (2) joint.
Fig. 17: Muffler Isolators & Right Rear Hanger

2. Slide the muffler isolators (1) off of the body mounted supports leaving the isolators attached to the
muffler.
3. Slide the muffler forward to allow the muffler to slide out of the isolator at the right rear hanger (2).
REMOVAL
Therefore, never attempt to service any part of the exhaust system until it
is cooled. Special care should be taken when working near the catalytic
converter. The temperature of the converter rises to a high level after a
short period of engine operation time.
WARNING: If torches are used when servicing the exhaust system, do not allow any
flame near the fuel lines or the fuel tank. Failure to follow these
instructions may result in possible serious or fatal injury.
MANUAL
2012 Fiat 500 Pop
Fig. 18: Muffler Pipe Flange To Maniverter Flange Mounting Nuts

1. Raise vehicle.
2. Remove the mounting nuts (3) from the front muffler pipe flange to maniverter flange.
3. Using a suitable jack stand. Support the exhaust system.
Fig. 19: Front Muffler Isolator

4. Remove the front muffler isolator (1).
MANUAL
2012 Fiat 500 Pop
Fig. 20: Rear Muffler Isolator

5. Remove the rear muffler (1) isolator.

6. Loosen exhaust pipe strap clamp (1).

7. Remove the muffler outlet pipe (3) from the resonator pipe (2).
INSTALLATION
INSTALLATION
MANUAL
2012 Fiat 500 Pop
Fig. 22: Muffler Isolators & Right Rear Hanger

1. Start at the right rear muffler support (2) and feed the muffler mounted support into the body mounted
isolator.
2. Slide the muffler mounted rubber isolators (1) onto the body mounted pins.

3. Attach the muffler (2) to the exhaust pipe (3).

4. Tighten the clamp (1) to 55 N.m (41 ft. lbs.).
5. Check for leaks.
INSTALLATION
MANUAL
2012 Fiat 500 Pop
Fig. 24: Muffler Pipe Flange To Maniverter Flange Mounting Nuts

1. Position the exhaust assembly into position.

2. Position a suitable jack stand to help aid in installing the exhaust assembly.
3. Install new gasket at the muffler to maniverter flange and install nuts (3). Tighten nuts to 25 N.m (18 ft.
lbs.).
Fig. 25: Front Muffler Isolator

4. Install the front muffler isolator (1).
MANUAL
2012 Fiat 500 Pop
Fig. 26: Rear Muffler Isolator

5. Install the rear muffler isolator (1).

6. Install the resonator inlet pipe (2) onto the muffler outlet pipe (3).
7. Tighten strap clamp (1) to 55 N.m (40 ft. lbs.).
8. Lower vehicle.
9. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.
10. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed.
RESONATOR, EXHAUST
MANUAL
2012 Fiat 500 Pop
REMOVAL
REMOVAL
Therefore, never attempt to service any part of the exhaust system until it
is cooled. Special care should be taken when working near the catalytic
converter. The temperature of the converter rises to a high level after a
short period of engine operation time.
WARNING: If torches are used when servicing the exhaust system, do not allow any
flame near the fuel lines or the fuel tank. Failure to follow these
instructions may result in possible serious or fatal injury.

1. Remove the rear strap clamp (1).
MANUAL
2012 Fiat 500 Pop
Fig. 29: Resonator & Isolators

2. Remove the isolators (1).

3. Remove the resonator (2) from the vehicle.
INSTALLATION
INSTALLATION

NOTE: When assembling exhaust system do not tighten clamp until components are
aligned and clearances are checked.
MANUAL
2012 Fiat 500 Pop
1. Loosely install the strap clamp (1) onto resonator pipe (2).
2. Position resonator pipe onto muffler pipe (3).
Fig. 31: Resonator & Isolators

3. Install the isolators (1) onto resonator (2).

4. Tighten strap clamp to 55 N.m (40 ft. lbs.).
SHIELD, HEAT
REMOVAL
REMOVAL
MANUAL
2012 Fiat 500 Pop
Fig. 32: Heat Shield & Fasteners

1. Raise vehicle on hoist.

2. Remove fasteners (2) attaching heat shield (1).
3. Remove heat shield(s).
INSTALLATION
INSTALLATION
Fig. 33: Heat Shield & Fasteners

1. Position heat shield(s) to underbody.
MANUAL
2012 Fiat 500 Pop
2. Install heat shield fasteners.

3. Inspect heat shield to exhaust system clearances and adjust as necessary.
4. Lower vehicle.
MANUAL

ENGINE Exhaust System FIAT 500

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ENGINE Exhaust System FIAT 500

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2012 Fiat 500 Pop

2012 ENGINE Exhaust System - Fiat 500

Exhaust System - Fiat 500

Fig. 1: Resonator/Pipe Assembly, Muffler/Pipe Assembly & Support Isolators

DIAGNOSIS AND TESTING

EXHAUST SYSTEM DIAGNOSIS CHART

4. Exhaust pipe leaking at 4. Tighten/replace flange attaching

1. Raise and support vehicle.

DESCRIPTION N.m Ft. Lbs. In. Lbs.

8404-EC - Exhaust Cone

The catalytic converter is part of the exhaust manifold, called a maniverter.

For removal of the maniverter. Refer to MANIFOLD, EXHAUST, REMOVAL or MANIFOLD,

1. Disconnect and isolate the negative battery cable.

Fig. 2: Air Cleaner Assembly, Intake Hose, Fittings & Clamp

Fig. 3: Upper Heat Shield Bolts & Nuts

Fig. 5: Turbocharger & Catalytic Converter Clamp

9. Loosen the catalytic converter clamp (2) at the turbocharger (1).

Fig. 6: Front Exhaust Pipe Support Bolt & Flange Nuts

12. Remove the front exhaust pipe support bolt (2).

Fig. 7: Catalytic Converter, Support Mount & Bolts

16. Unbolt the 4 converter mount bolts (3).

Fig. 8: Catalytic Converter Gasket Ring

19. Remove the catalytic converter gasket ring.

Fig. 9: Catalytic Converter Gasket Ring

1. Install the converter to turbo seal ring (1).

Fig. 10: Turbocharger & Catalytic Converter Clamp

2. Install the catalytic converter assembly (3).

5. Install the catalytic converter v-clamp (2) at the turbocharger (1).

Fig. 11: Catalytic Converter, Support Mount & Bolts

8. Install the lower catalytic converter support bracket (2).

Fig. 14: Upper Heat Shield Bolts & Nuts

21. Install the air cleaner assembly (1).

Fig. 16: Exhaust Pipe, Muffler Pipe & Clamp

Courtesy of CHRYSLER GROUP, LLC

Fig. 17: Muffler Isolators & Right Rear Hanger

Fig. 18: Muffler Pipe Flange To Maniverter Flange Mounting Nuts

Fig. 19: Front Muffler Isolator

4. Remove the front muffler isolator (1).

Fig. 20: Rear Muffler Isolator

5. Remove the rear muffler (1) isolator.

Fig. 21: Exhaust Pipe, Muffler Pipe & Clamp

6. Loosen exhaust pipe strap clamp (1).

Fig. 22: Muffler Isolators & Right Rear Hanger

Fig. 23: Exhaust Pipe, Muffler Pipe & Clamp

3. Attach the muffler (2) to the exhaust pipe (3).

Fig. 24: Muffler Pipe Flange To Maniverter Flange Mounting Nuts

1. Position the exhaust assembly into position.

Fig. 25: Front Muffler Isolator

4. Install the front muffler isolator (1).

Fig. 26: Rear Muffler Isolator

5. Install the rear muffler isolator (1).

Fig. 27: Exhaust Pipe, Muffler Pipe & Clamp

Fig. 28: Exhaust Pipe, Muffler Pipe & Clamp

1. Remove the rear strap clamp (1).

Fig. 29: Resonator & Isolators

2. Remove the isolators (1).

Fig. 30: Exhaust Pipe, Muffler Pipe & Clamp

Fig. 31: Resonator & Isolators

3. Install the isolators (1) onto resonator (2).

Fig. 32: Heat Shield & Fasteners

1. Raise vehicle on hoist.

Fig. 33: Heat Shield & Fasteners

1. Position heat shield(s) to underbody.

2. Install heat shield fasteners.