Installation

1. Install the ICU back in the vehicle and on its mounting bracket using the reverse order of its removal.
2. Install isolators, washers and attaching bolts, mount the ICU to its mounting bracket.
3. Tighten the 3 HCU mounting bolts to a torque of 11 Nm (97 inch lbs.).

CAUTION: Before installing the 25 way connector in the CAB be sure that the seal is properly installed in the connector.

4. Install the 25 way connector into the socket on the CAB. The connector is installed using the following procedure: Position the 25 way connector in the socket on the CAB and carefully push it down as far as it will go. When connector is fully seated into the CAB socket push in the connector lock as far as it will go. This will pull the 25 connector into the socket on the CAB and lock it in the installed position.
5. Install the 2 bolts attaching the back legs of the HCU mounting bracket to the front suspension crossmember.
6. Install the bolt attaching the front leg of the HCU mounting bracket to the front suspension crossmember.
7. Tighten the 3 bolts mounting the HCU mounting to the front suspension crossmember to a torque of 28 Nm (250 inch lbs.).
8. Install the primary and secondary brake tubes coming from the master cylinder in the HCU inlet ports.
9. Install the 4 chassis brake tubes in the outlet ports on the HCU.

Torquing Primary And Secondary Brake Tube Nut:

Torquing Chassis Brake Tube Nuts:

10. Using a crow foot tighten all of the brake tube nuts to a torque of 17 Nm (145 inch lbs.).
11. Install the HCU heat shield on the HCU mounting bracket. Install and securely tighten the attaching bolt.
12. Install exhaust system in vehicle using the reverse steps of its removal.
13. Install right side engine compartment splash shield back on the vehicle.
14. Lower vehicle.
15. Remove brake pedal holding tool.
16. Install the remote ground cable onto the ground stud located on left shock tower. Install the remote ground cable attaching nut and tighten to a torque of 28 Nm (250 inch lbs.).
17. Bleed the base brakes and the ABS brakes hydraulic system.
18. Road test vehicle to ensure proper operation of the base and ABS systems.