Unit, Brake Operating: Installation

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.

NOTE:

If the reservoir was removed during unit removal, install the reservoir prior to installation of the BOU to the vehicle.

With the aid of an assistant, guide the BOU into the dash panel opening.
Insert the brake rod bushing into the pocket of the brake pedal assembly.

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Install the four nuts (1), tighten to 18 Nm (13 lbf-ft).

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Install the brake lines (3) to the BOU (1). Tighten the M12 Nuts to 18 Nm (13 lbf-ft) and the M14 Nuts to 25 Nm (18 lbf-ft).
Plug the brake pedal travel sensor connector (2) into the BOU (1).
Remove the electronic vehicle control unit (EVCU) bracket bolts (1).

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Install the EVCU. Install the bracket bolts (1). Tighten the EVCU bracket bolts to 24 Nm (18 lbf-ft).

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Connect the two electronic vehicle control unit (EVCU) electrical connectors (1).

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Install the hose (3) to the reservoir (1). Position the clamp.
Plug the brake fluid level sensor connector (2) into the reservoir (1).

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Install the PDC bracket (2).
Position the bonding wire over the left rear stud. Tighten the nut to 9 Nm (80 lbf-in).
Install the PDC bracket nuts (1). Tighten the nuts to 18 Nm (13 lbf-ft).

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Insert the harness retainer (1) into the bracket (2).

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Install the PDC to the bracket. Install the nuts. Tighten to 9 Nm (80 lbf-in).

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Plug in the PDC connectors (1).

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Install the PDC onto the bracket.

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Install a NEW gasket to the suction line fitting (1).
Connect the suction line (1) to the HV battery chiller block (2). Tighten the nut to 11 Nm (8 lbf-ft).

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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 lbf-ft).

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Install the bolt (2) that secures the suction line retainer (1) to the power distribution center. Tighten to 9 Nm (80 lbf-in).

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Connect the under-hood fuse box connectors (1, 2).

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Connect the Intelligent Battery Sensor (IBS) two wire connector (1).
Install the battery tray. Refer to TRAY, BATTERY, INSTALLATION .
Install the battery. Refer to BATTERY, INSTALLATION .
Recharge the air-condition system. Refer to REFRIGERANT SYSTEM CHARGE .
Fill the brake fluid reservoir.

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NOTE:
Do not use any lubricants on the rubber grommets.
Inspect the rubber grommets (1) for secure fit in the cover.
Position the beauty cover over the four mounting posts.

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Using palm pressure, push down onto the cover at the four points (1) above the posts until fully seated.
Pinch the power electronics coolant reservoir return hose and insert into the notch.
Power up the vehicle. Refer to HIGH-VOLTAGE POWER UP .
Perform the Repair Bleed Verification routine. Refer to ELECTRIC VEHICLE CONTROL SYSTEM, STANDARD PROCEDURE .