A. Fiat 500 (FF)
SPECIAL NOTE:All components for the hydraulic brake system must be replaced.
Do not attempt to flush out brake tubes, internal corrosion may have occurred and cannot not be removed by flushing.
Also, vehicles equipped with a manual transmission must have all the hydraulic clutch actuator components replaced, because the brake and clutch systems use a common reservoir.
1. Remove and save the battery.
2. Remove and save the air cleaner assembly.
3. Disconnect the two Powertrain Control Module (PCM) electrical connectors (Figure 1).
4. Remove and save the battery tray and PCM as an assembly.
5. Remove and discard the brake master cylinder from the brake booster.
6. Remove and save the Antilock Brake System (ABS) Hydraulic Control Unit (HCU) and remove and discard all related steel brake tubes from the master cylinder to the HCU.
7. Remove and discard the brake tube retaining clip that holds the four brake steel brake tubes located near the brake booster.
8. For vehicles equipped with a manual transmission, remove the hydraulic clutch slave cylinder using the following procedure:
a. Cut the black plastic hydraulic clutch hose at the clutch master cylinder.
b. Remove and save the two clutch slave cylinder mounting bolts (Figure 2).
c. Remove and discard the hydraulic clutch slave cylinder and the clutch master cylinder-to-clutch slave cylinder plastic tube from the top of the transaxle.
9. For vehicles equipped with a manual transmission, replace the clutch master cylinder using the following procedure:
NOTE:
The clutch master cylinder retaining bolts are very difficult to see and even more difficult to remove. Extreme patience and perseverance is required.
a. Remove the upper support bracket located under the instrument panel.
b. Carefully remove the brake light assembly.
c. Disconnect the steering shaft at the floor (Figure 3).
CAUTION:
Do not turn the steering wheel or steering gear input shaft while disconnected. Clock spring orientation will be lost and the clockspring will have to be centered or damage to the clockspring will occur.
d. Remove and save the six (6) brake pedal retaining nuts.
e. Carefully remove and save the brake booster from the vehicle.
f. Pull the brake pedal assembly rearward off the upper retaining stud.
g. Carefully slide the brake pedal assembly towards the center of the vehicle to gain access to the clutch master cylinder mounting bolts.
CAUTION:
Do not remove the brake pedal assembly from the vehicle.
h. Using a Torx-T30 socket, remove and save the two clutch master cylinder retaining bolts.
i. Remove and discard the original clutch master cylinder.
j. Place the new clutch master cylinder into position.
k. Install the clutch master cylinder retaining bolts.
l. Place the brake pedal assembly into position.
m. Place the brake booster into position.
n. Install the six (6) brake pedal retaining nuts and tighten them to 17 ft. lbs. (23 Nm).
o. Install the brake light switch into the brake pedal assembly.
p. Connect the steering shaft to the rack and pinion. Then install a new pinch bolt.
q. Install the upper support bracket under the instrument panel.
10. Lift the vehicle on an appropriate hoist.
11. Remove all four (4) wheel and tire assemblies.
12. Remove and save the engine splash shield.
13. Remove the left side rocker panel retaining screw to gain access to the some of the left underbody splash shield retaining fasteners.
14. Remove and save the left side underbody splash shield.
15. Remove and save the fuel and brake tube plastic splash shields (Figure 4).
16. Remove and discard both rear brake calipers, rubber caliper flex hoses, and swing arm steel brake tubes.
NOTE:
Do not remove the rear brake pads from the brake caliper adapters. The rear brake pads will be reused.
17. Remove and discard the body-to-swing arm rubber flex hoses.
18. Using a sharp drill bit, drill out the rivet heads for the left splash shield support bracket.
Then remove and save the splash shield support bracket (Figure 5).
19. Remove and discard the HCU-to-swing arm brake steel tube for the left rear wheel.
20. Disconnect the rubber exhaust hanger located behind the exhaust resonator.
21. Disconnect the two rubber exhaust hangers located by the muffler and lower the exhaust system until it rests against the rear suspension swing arm.
22. Remove the HCU-to-swing arm steel brake tube for the right rear wheel using the following procedure:
a. Place a jack under the fuel tank and gently support the fuel tank (Figure 6).
b. Remove and save the fuel tank straps and exhaust heat shield as an assembly.
c. Carefully push the fuel tank rearward slightly to gain access to the right rear wheel HCU-to-swing arm steel brake tube and disconnect the plastic retaining clips from the retaining studs.
d. Carefully remove and discard the original HCU-to-swing arm steel brake tube for the right rear brake.
23. Install the new right rear HCU-to-swing arm steel brake tube into position.
24. Install the plastic retaining clips for the right rear HCU-to-swing arm steel brake tube that hold the brake tube next to the fuel tank.
25. Install the left rear HCU-to-swing arm steel brake tube.
26. Install the right and left side body-to-swing arm rubber flex hoses. Tighten the flare nuts to 142 in. lbs. (16 Nm).
27. Install the fuel tank straps and exhaust heat shield as an assembly.
28. Remove the jack from under the fuel tank.
29. Connect the two rubber exhaust hangers at the muffler.
30. Connect the rubber exhaust hanger at the exhaust resonator.
31. Using rivet gun HUK-AK175A or equivalent, rivet the left rear underbody splash shield support bracket to the floor pan using the supplied rivets (Figure 7).
32. Clip the steel brake tubes to the bottom of the floor pan.
33. Install the fuel and brake tube plastic splash shields that run along the bottom of the floor pan (Figure 4).
34. Install the left side underbody splash shield.
35. Install the left rocker panel retaining screws.
36. Partially lower the vehicle from the hoist.
37. Install new right and left side swing arm steel brake tubes (Figure 8).
38. Install the rubber flex hoses onto the rear brake calipers.
39. Install the rear brake calipers. Tighten the brake caliper retaining bolts to 25 ft.lbs. (34 Nm).
40. Connect the right and left rear brake caliper rubber flex hoses to the swing arm steel brake tubes. Tighten the flare nuts to 142 in. lbs. (16 Nm).
41. Connect the park brake cables to the rear brake calipers.
42. Lower the vehicle from the hoist.
43. For vehicles equipped with a manual transaxle, install the hydraulic clutch slave cylinder onto the transaxle. Tighten the mounting bolts to 15 ft. lbs. (20 Nm).
44. For vehicles equipped with a manual transaxle, connect the clutch master cylinder-to-clutch slave cylinder plastic tube.
45. Remove and discard the right and left front brake calipers and rubber flex hoses.
46. Remove and discard the left front steel brake tube.
47. Remove and discard the right front steel brake tube.
48. Install the new right side front steel brake tube.
49. Install the new left side front steel brake tube.
50. Install the new plastic brake tube clip that holds the four steel brake tubes at the HCU.
51. Transfer the HCU bracket from the original HCU to the new HCU (Figure 9).
52. Install the new HCU to the vehicle.
53. Install the brake master cylinder using new mounting nuts. Tighten the brake master cylinder mounting nuts to 18 ft. lbs. (25 Nm).
54. Install both brake master cylinder-to-HCU steel brake tubes. Tighten the tube nuts to 150 in. lbs. (17 Nm).
55. Install new rubber flex hoses onto the right and left front brake calipers (Figure 10).
56. Install the new front brake calipers using the original brake pads. Tighten the front brake caliper guide pin bolts to 21 ft. lbs. (28 Nm).
57. Connect the front brake caliper flex hoses to the steel brake tubes (Figure 11).
58. Fill the brake master cylinder reservoir with Mopar D.O.T. 3 brake fluid.
59. For vehicles equipped with a manual transaxle, bleed the clutch hydraulic actuation system at the slave cylinder.
60. Connect the HCU electrical connector to the HCU control module.
61. Install the battery tray and PCM as an assembly.
62. Connect the two PCM connectors to the PCM. Be sure to engage the electrical connector locks.
63. Install the battery.
64. Install the air cleaner assembly.
65. Bleed all four (4) brake calipers.
66. Connect a battery charger to the vehicles battery.
67. Connect the wiTECH scan tool to the vehicle.
68. Calibrate the "G" sensor under "System Test".
69. Perform the "ABS Static Test".
70. Clear all Diagnostic Trouble Codes (DTCs).
71. Check for proper brake pedal operation and feel. If the brake pedal feels soft, repeat the bleed procedure.
72. Remove the wiTECH scan tool from the vehicle.
73. Install the four wheel & tire assemblies. Tighten the lug bolts to 75 ft. lbs. (100 Nm) for aluminum wheels or 63 ft. lbs (85 Nm) for steel wheels.
74. Install the engine underbody splash shield (Figure 12).
75. Lower the vehicle from the hoist.