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Home >> Fiat >> 2016 >> 500 Turbo, Standard Trans >> Repair and Diagnosis >> External Pages >> Different car >> Section 34 (Electric Powertrain System - 500 - Electric) >> Electric Vehicle Battery System >> Controller, Regenerative Brake (RBC) >> Removal >> Removal

Controller, Regenerative Brake (RBC): Removal: Removal

WARNING: This page is about a different car, the 2015 Fiat 500. 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 STANDARD PROCEDURE .
  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 IMS (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 and discard  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. Pinch off the reservoir supply hose (3) to prevent draining the brake fluid reservoir (1) when the Regenerative Brake Controller (RBC) is removed.
  22. Place a drain pan under the vehicle below RBC.
  23. Place rags or absorbent pad(s) under the RBC to prevent fluid from contacting painted surfaces.
    Fig 14: RBC Connector & Latch
    GC0157783Courtesy of CHRYSLER GROUP, LLC
  24. Rotate the RBC connector latch (1) downward. Disconnect the connector (2).
    Fig 15: RBC Module & Brake Lines
    GC0157872Courtesy of CHRYSLER GROUP, LLC
  25. Remove the four brake lines (1) from the RBC module (2).
    Fig 16: RBC Mount Isolator Nuts & Connector
    GC0157928Courtesy of CHRYSLER GROUP, LLC
  26. Loosen, but do not remove  the RBC mount isolator nuts (1).
  27. Position the connector (2) out of the way to prevent damage during RBC module removal.
  28. While holding the brake lines clear, carefully remove the RBC module from the vehicle.
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