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Booster, Power Brake: 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.
Fig 1: Engine Cover
GC0152354Courtesy of CHRYSLER GROUP, LLC
CAUTION:

The vacuum in the power brake booster must be pumped down before removing the master cylinder to prevent the booster from sucking in any contamination. This can be done by pumping the brake pedal while the engine is not running until a firm brake pedal is achieved.

NOTE:

Before proceeding, refer to CAUTION  and WARNING  .

  1. With the engine not running, pump the brake pedal 4-5 strokes until the pedal feel is firm.
  2. Remove the engine cover (1).
    Fig 2: Air Cleaner Body Assembly
    GC0152416Courtesy of CHRYSLER GROUP, LLC
  3. Disconnect and isolate the battery negative cable from its post on the battery.
  4. Remove the air cleaner body (5). Refer to BODY, AIR CLEANER, REMOVAL - 1.4L 16-Valve or BODY, AIR CLEANER, REMOVAL - 1.4L 16-Valve Turbo.
    Fig 3: PCM Electrical Connectors
    GC0152393Courtesy of CHRYSLER GROUP, LLC
  5. Disconnect and remove the battery (Refer to REMOVAL ).
  6. Disconnect the powertrain control module (PCM) electrical connectors (1 and 2).
    Fig 4: Battery Tray, Connectors, Retainers, Nut & Bolts
    GC0152563Courtesy of CHRYSLER GROUP, LLC
  7. Disengage two starter wire harness retainers (6) from the battery tray (3).
  8. Disengage two engine wire harness retainers (4) from the battery tray (3).
  9. Disengage the engine wire harness connector (2) from the battery tray (3) and reposition the wire harness.
  10. Remove the nut (5) and two bolts (1).
    Fig 5: PCM, Retainers, Ground Strap & Nuts
    GC0152394Courtesy of CHRYSLER GROUP, LLC
  11. Open the two wire harness retainers (3) and reposition the wire harness.
  12. Remove the battery tray with the PCM (2) attached.
    Fig 6: Antilock Brake Module (ABM) & Connector Cover
    GC0152494Courtesy of CHRYSLER GROUP, LLC
  13. Disconnect the Antilock Brake Module (ABM) harness connector (2) from the ABM (1). To do so:
    1. Lift the connector cover (2) until it locks into position straight up and down.
    2. The connector can then be pulled straight up and off the ABM (1).
    Fig 7: Integrated Control Unit (ICU) Assembly
    GC0152491Courtesy of CHRYSLER GROUP, LLC
  14. Siphon as much fluid as possible from master cylinder reservoir.
  15. Remove brake tubes from Integrated Control Unit (ICU) (3), including two fittings (4) from the master cylinder.
  16. Remove the two mounting screws (5) attaching the ICU (3) mounting bracket to the body.
  17. Pull the ICU (3) away from the body to separate mounting pin from body hole (1).
  18. Move the brake tubes around as necessary without bending them and remove the ICU with bracket from the vehicle.
    Fig 8: Fluid Level Switch, Reservoir, Brake Tubes & Nuts
    GC0152571Courtesy of CHRYSLER GROUP, LLC
  19. Disconnect the vacuum hose from the check valve on the power brake booster.
  20. Remove brake fluid switch (3) from master cylinder reservoir (4).
  21. Remove master cylinder retaining nuts (2) and remove master cylinder from vehicle.
    Fig 9: Lower Coupling Bolt
    GC0084367Courtesy of CHRYSLER GROUP, LLC
  22. Remove intermediate shaft pinch bolt (3) and separate intermediate shaft (2) from steering gear pinion shaft (4).
    Fig 10: Brake Pedal Sled & Nuts
    GC0152493Courtesy of CHRYSLER GROUP, LLC
  23. Press the tabs together and separate the booster push rod from the pedal assembly
  24. Remove the four nuts (3) attaching the power brake booster to the dash panel.
    Fig 11: Power Brake Booster, Master Cylinder & Push Rod
    GC0152492Courtesy of CHRYSLER GROUP, LLC
  25. Slide the power brake booster (2) forward until its mounting studs clear the dash panel, then remove it through the engine compartment.
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