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Unit, Brake Operating: Removal: Removal

WARNING: This page is about a different car, the 2014 Fiat 500e. However, it is still accessible from the selected car via links, so may be relevant.
WARNING:

When performing any repairs that involve contact with high voltage components or systems, the technician performing repairs on the vehicle must verify that the system remains powered down during high voltage repairs.

  • This must be done by removing the service disconnect.
  • The high voltage check out procedure must also be performed to ensure that the vehicle is properly powered down.
  • The technician must know the whereabouts of the service disconnect throughout the repair.
  • The technician must ensure that no one reconnects the service disconnect while service is being performed.
  • The technician must recheck that the service disconnect has not been reinstalled in cases where the vehicle was unattended.
  1. Power down the high-voltage system. Refer to ELECTRIC VEHICLE CONTROL SYSTEM, STANDARD PROCEDURE .
  2. Disconnect the 12 volt battery.
    Fig 1: Beauty Cover Attaching Points
    GC0157873Courtesy of CHRYSLER GROUP, LLC
  3. Pinch the power electronics coolant reservoir return hose with two fingers and disconnect the hose from cover notch.
  4. Grasp the beauty cover at attaching points (1) as shown in illustration.
    Fig 2: Removing Beauty Cover
    GC0157704Courtesy of CHRYSLER GROUP, LLC
  5. Lift the beauty cover (1) straight upward.
  6. Recover the air-conditioning system. Refer to REFRIGERANT SYSTEM RECOVERY .
  7. Remove the battery. Refer to BATTERY, REMOVAL .
  8. Remove the battery tray. Refer to TRAY, BATTERY, REMOVAL .
    Fig 3: Intelligent Battery Sensor & Connector
    GC0157694Courtesy of CHRYSLER GROUP, LLC
  9. Disconnect the Intelligent Battery Sensor (IBS) two wire connector (1). Position the IBS (2) aside.
    Fig 4: Under-Hood Fusebox Connectors
    GC0157607Courtesy of CHRYSLER GROUP, LLC
  10. Disconnect the under-hood fusebox connectors (1, 2).
    Fig 5: Suction Line Retainer & Bolt
    GC0157761Courtesy of CHRYSLER GROUP, LLC
  11. Remove the bolt (2) that secures the suction line retainer (1) to the power distribution center (PDC) bracket.
    Fig 6: Suction Line & Evaporator Block
    GC0157826Courtesy of CHRYSLER GROUP, LLC
  12. Disconnect the suction line (1) at the evaporator block (2).
    Fig 7: Suction Line & HV Battery Chiller Block
    GC0157870Courtesy of CHRYSLER GROUP, LLC
  13. Disconnect the suction line (1) at the HV battery chiller block (2).
    Fig 8: Under-Hood Fuse Box Tabs
    GC0157688Courtesy of CHRYSLER GROUP, LLC
  14. Release the under-hood fuse box tabs (1) and position the fuse box to the side.
    Fig 9: PDC Connectors
    GC0157724Courtesy of CHRYSLER GROUP, LLC
  15. Unplug the PDC connectors (1).
    Fig 10: PDC Mounting Nuts
    GC0157729Courtesy of CHRYSLER GROUP, LLC
  16. Remove the PDC mounting nuts (1) and position the PDC to the side.
    Fig 11: PDC Bracket & Harness Retainer
    GC0157703Courtesy of CHRYSLER GROUP, LLC
  17. Release the harness retainer (1) from the PDC bracket (2).
    Fig 12: PDC Bracket & Nuts
    GC0157740Courtesy of CHRYSLER GROUP, LLC
  18. Remove the four attaching nuts (1) that secure the PDC bracket (2).
  19. Remove the bonding wire nut, position the bonding wire to the side.
  20. Remove the PDC bracket (1) from the vehicle.
    Fig 13: Brake Fluid Reservoir, Supply Hose & Connector
    GC0157830Courtesy of CHRYSLER GROUP, LLC
  21. Unplug the brake fluid level sensor connector (2).
  22. Remove the brake fluid from the reservoir with a clean  siphon.
  23. Pinch off the reservoir supply hose (3) to prevent debris from entering the hose when removed.
  24. Place a drain pan under the vehicle below the brake fluid reservoir.
  25. Place rags or absorbent pad(s) under the brake operating unit (BOU) to prevent fluid from contacting painted surfaces.
  26. Reposition the hose clamp to allow for removal of the hose.
  27. Remove the hose (3) from the reservoir (2).
    Fig 14: Electronic Vehicle Control Unit (EVCU) Bracket Bolts
    GC0157730Courtesy of CHRYSLER GROUP, LLC
  28. Remove the electronic vehicle control unit (EVCU) bracket bolts (1).
    Fig 15: Electronic Vehicle Control Unit (EVCU) & Electrical Connectors
    GC0157698Courtesy of CHRYSLER GROUP, LLC
  29. Disconnect the two EVCU electrical connectors (1), and remove the EVCU (2).
    Fig 16: BOU, Brake Pedal Travel Sensor Connector & Hydraulic Lines
    GC0157921Courtesy of CHRYSLER GROUP, LLC
  30. Unplug the brake pedal travel sensor connector (2) from the BOU (1).
  31. Remove the hydraulic lines (3) from the BOU (1).
    Fig 17: BOU & Nuts
    GC0157650Courtesy of CHRYSLER GROUP, LLC
  32. Remove the four nuts (1) that secure the BOU to the dash panel.
  33. With the aid of an assistant, slowly guide the BOU forward. Capture the brake rod bushing that is located between the pedal (2) and BOU shaft as the unit is moved forward.
  34. Remove the BOU from the vehicle.
    NOTE:

    It will be necessary to guide the BOU past the brake lines.

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