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Home >> Fiat >> 2015 >> 500L Trekking, Automatic Trans >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Base Brakes - (Service Information) - 500L >> Hydraulic/Mechanical >> Booster, Power Brake >> Installation >> Installation

Booster, Power Brake: Installation: Installation

Fig 1: Booster Seal
GC0082140Courtesy of CHRYSLER GROUP, LLC
NOTE:

Before power brake booster (1) installation, be certain a NEW dash seal (2) is installed on the booster mounting studs.

Fig 2: Power Brake Booster, Master Cylinder & Push Rod
GC0152492Courtesy of CHRYSLER GROUP, LLC
  1. Install the power brake booster (2) by sliding the push rod (3) and studs through the dash panel and into mounting position.
    Fig 3: Brake Pedal Sled & Nuts
    GC0152493Courtesy of CHRYSLER GROUP, LLC
  2. Under the instrument panel, install the four power brake booster mounting nuts (3).
  3. Tighten the brake pedal/booster mounting nuts to 23 N.m (17 ft. lbs.).
    Fig 4: Retainer & Clips
    GC0155758Courtesy of CHRYSLER GROUP, LLC
  4. Install the power brake booster push rod and retainer (2) into NEW booster rod keeper, ensuring that the clips (1) are engaged.
  5. Install and adjust the stop lamp switch in the brake pedal bracket. Refer to SWITCH, STOP LAMP, INSTALLATION .
    Fig 5: Identifying Pinch Bolt, Intermediate Shaft & Steering Gear Shaft
    GC0158840Courtesy of CHRYSLER GROUP, LLC
  6. Install intermediate shaft (1) to steering gear pinion shaft (3) and install a NEW  pinch bolt (2). Tighten pinch bolt to 55 N.m (40 ft. lbs.).
    Fig 6: Seal On Rear Of Master Cylinder
    GC0083936Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The master cylinder must be bled before installing it on the vehicle.

  7. Bench bleed the master cylinder. Refer to MASTER CYLINDER, BRAKE, STANDARD PROCEDURE .
  8. Wipe the face of the power brake booster clean where the vacuum seal on the rear of the master cylinder comes in contact when it's installed. Do not get any cleaner or debris inside the booster.
    CAUTION:

    When installing a master cylinder on the vehicle, a NEW vacuum seal (2) MUST be installed on the master cylinder mounting flange (1).

  9. If the master cylinder does not have a new vacuum seal (2) on the mounting flange (1), remove it. Install a NEW vacuum seal on the master cylinder mounting flange making sure the seal fits squarely in its groove.
    Fig 7: Master Cylinder Retaining Nuts
    GC0158830Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    If resistance is met during master cylinder insertion into power brake booster, the master cylinder push rod may not be lined up with the booster push rod. Remove the master cylinder, realign and insert it again.

  10. Line up the master cylinder mounting holes with the mounting studs on the power brake booster. Ensure the master cylinder piston push rod lines up with the booster push rod, then carefully slide the master cylinder into the power brake booster until it contacts the face of the booster.
  11. Install two NEW master cylinder mounting nuts (1). Tighten each nut to 25 N.m (18 ft. lbs.).
    Fig 8: Clutch Actuator Port Plug
    GC0152572Courtesy of CHRYSLER GROUP, LLC
  12. If equipped with a manual transaxle and a new reservoir is being installed, remove the plug (1) for the clutch actuator port.
  13. If equipped with a manual transaxle, slide the clutch actuator hose onto the reservoir port. Install the hose clamp just past the upset bead on the port.
    Fig 9: Identifying Integrated Control Unit Components
    GC0158829Courtesy of CHRYSLER GROUP, LLC
  14. Position and slide the Integrated Control Unit (ICU) onto the mounting pin on the body.
  15. Install mounting fasteners (3) and tighten to 23 N.m (17 ft. lbs.).
  16. Install brake tubes (2, 4). Tighten tube nuts to 17 N.m (150 in. lbs.).
  17. Connect the wiring harness connector (6) to the brake fluid level switch.
  18. Connect the vacuum hose to the check valve on the brake booster.
    CAUTION:

    Before installing the ABM harness connector on the ABM, be sure the seal is properly installed in the connector.

  19. Insert the ABM wiring harness connector (1) into the socket of the ABM and close the cover (5), locking the connector in place.
    Fig 10: PCM, Retainers, Ground Strap & Nuts
    GC0152394Courtesy of CHRYSLER GROUP, LLC
  20. Position the battery tray and PCM in the vehicle. Route the wire harness and close the wire harness retainers (3).
    Fig 11: Battery Tray, Connectors, Retainers, Nut & Bolts
    GC0152563Courtesy of CHRYSLER GROUP, LLC
  21. Install the battery tray (3) with one nut (5) and two bolts (1) tightened to 25 N.m (18 ft. lbs.).
  22. Engage the engine wire harness connector (2) to the battery tray (3).
  23. Engage two engine wire harness retainers (4) to the battery tray (3).
  24. Engage two starter wire harness retainers (6) to the battery tray (3).
    Fig 12: PCM Electrical Connectors
    GC0152393Courtesy of CHRYSLER GROUP, LLC
  25. Connect the powertrain control module (PCM) electrical connectors (1 and 2).
  26. Connect the negative (ground) cable on the battery.
  27. Fill the master cylinder reservoir to the proper level.
    Fig 13: Engine Cover
    GC0152354Courtesy of CHRYSLER GROUP, LLC
  28. Install the engine cover (1).
    WARNING:

    Be certain a firm brake pedal is achieved prior to attempting to operate the vehicle. If a firm brake pedal cannot be achieved, bleed the brake hydraulic system and check for leaks.

  29. Install a scan tool to initialize the ABM and perform the following:
    1. Clear any faults.
    2. Fill the master cylinder to the proper fill level and bleed the base and ABS hydraulic systems. Refer to STANDARD PROCEDURE  for Base hydraulic systems or STANDARD PROCEDURE for ABS hydraulic systems .
    3. Check for leaks.
    4. Perform the ABS Verification Test. Refer to STANDARD PROCEDURE .
  30. Road test the vehicle to ensure proper operation of the brakes.
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