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Home >> Fiat >> 2019 >> 500 Lounge, Automatic Trans >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 6 (Electric Powertrain System - 500 - Electric) >> Electric Vehicle Battery System >> Controller, Regenerative Brake (RBC) >> Installation

Controller, Regenerative Brake (RBC): Installation

WARNING: This page is about a different variant/trim than selected.
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 power down 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.

The hardware to secure the PDC bracket to the cradle MUST BE REPLACED when servicing. 

GC0157928Courtesy of CHRYSLER GROUP, LLC
  1. Install the Regenerative Brake Controller (RBC) onto the mount tabs.
  2. Tighten the nuts (1) to 9 N.m (80 in. lbs.).
  3. Connect the controller connector (2).
    GC0157872Courtesy of CHRYSLER GROUP, LLC
  4. Install the brake lines (1) to the RBC (2).
  5. Tighten the M12 Nuts to 18 N.m (13 ft. lbs) and the M14 Nuts to 25 N.m (18 ft. lbs).
  6. Remove the hose pinch tool from the supply hose.
    GC0157740Courtesy of CHRYSLER GROUP, LLC
  7. Install the PDC bracket (2).
  8. Position the bonding wire over the left rear stud. Tighten the nut to 9 N.m (80 in. lbs.).
  9. Install the NEW  PDC bracket nuts (1). Tighten the nuts to 18 N.m (13 ft. lbs.).
    GC0157703Courtesy of CHRYSLER GROUP, LLC
  10. Insert the harness retainer (1) into the bracket (2).
    GC0157729Courtesy of CHRYSLER GROUP, LLC
  11. Install the PDC to the bracket. Install the nuts and tighten to 9 N.m (80 in. lbs.).
    GC0157724Courtesy of CHRYSLER GROUP, LLC
  12. Plug in the PDC connectors (1).
    GC0157688Courtesy of CHRYSLER GROUP, LLC
  13. Install the PDC onto the bracket.
    GC0157870Courtesy of CHRYSLER GROUP, LLC
  14. Install a NEW  gasket to the suction line fitting (1).
  15. Connect the suction line (1) to the HV battery chiller block (2). Tighten the nut to 11 Nm (8 ft. lbs.).
    GC0157826Courtesy of CHRYSLER GROUP, LLC
  16. Install a NEW  seal to the suction line fitting (1). Install the line to the evaporator block (2). Tighten the nut to 11 Nm (8 ft. lbs.).
    GC0157761Courtesy of CHRYSLER GROUP, LLC
  17. Install the bolt (2) that secures the suction line retainer (1) to the power distribution center and tighten to 9 N.m (80 in. lbs.).
    GC0157607Courtesy of CHRYSLER GROUP, LLC
  18. Connect the under-hood fusebox connectors (1, 2).
    GC0157694Courtesy of CHRYSLER GROUP, LLC
  19. Connect the Intelligent Battery Sensor (IBS) two wire connector (1).
  20. Install the battery tray. Refer to TRAY, BATTERY, INSTALLATION .
  21. Install the battery. Refer to BATTERY, INSTALLATION .
  22. Recharge the air-condition system. Refer to REFRIGERANT SYSTEM CHARGE .
  23. Fill the brake fluid reservoir.
    GC0157771Courtesy of CHRYSLER GROUP, LLC
  24. Do not use any lubricants on the rubber grommets. 
  25. Inspect the rubber grommets (1) for secure fit in the cover.
  26. Position the beauty cover over the four mounting posts.
    GC0157873Courtesy of CHRYSLER GROUP, LLC
  27. Using palm pressure, push down onto the cover at the four points (1) above the posts until fully seated.
  28. Pinch the power electronics coolant reservoir return hose and insert into the notch.
  29. Power up the vehicle. Refer to HIGH-VOLTAGE POWER UP .
  30. Perform the Repair Bleed Verification routine. Refer to BRAKE OPERATING UNIT - BLEED PROCEDURE .
    NOTE:

    Any time the scan tool is communicating with the Regenerative Brake Control Module while in motion, the brake pedal will become stiff requiring extra effort to apply the brakes. This will remain active up to 10 kilometers per hour (6 mph). Once 10 kilometers per hour is exceeded, the pedal feel will return to normal. While the RBC is in DIAGNOSTICS MODE the ABS, ESC, RBS and BRAKE warning lamps will be illuminated.

NOTE:

If this Electronic Control Unit (ECU) is being replaced with a new unit, a diagnostic scan tool MUST be used to determine if alignment of the PROXI configuration data into the new ECU is needed. If PROXI alignment is needed, follow the routine outlined in the diagnostic scan tool for PROXI Configuration Alignment under the Body Control Module (BCM) Miscellaneous Functions menu.

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