ICU (Integrated Control Unit)
ICU (Integrated Control Unit)REMOVAL - ICU1. Remove the remote ground cable from the ground stud on the right strut tower.
Correctly Isolated Remote Ground Cable:
2. Correctly isolate remote ground cable when servicing vehicle by installing the ground cable insulator on the strut tower ground stud as shown in and installing the nut on the stud. This will prevent accidental grounding of the remote ground cable.
3. Using a brake pedal positioning tool such as shown, depress brake pedal past its first 1 inch of travel and hold in this position. This will isolate the master cylinder reservoir from the brake hydraulic system, not allowing the brake fluid to drain out of the reservoir.
4. Remove the bolt and 2 nuts securing the speed control servo to vehicle. Disconnect the wire harness connector from speed control servo. Leaving the cable attached to the speed control servo, move it aside, out of the way.
Transmission Controller Mounting:
5. Remove the screw attaching the washer bottle filler neck to the vehicle. Move neck to the side without loosening the filler tube.
6. Remove the nut and bolt holding the transmission controller and bracket to vehicle. Lift transmission controller up and move away from mounting position.
7. Using Mopar Brake Parts Cleaner or an equivalent, thoroughly clean all surfaces of the HCU. Also, thoroughly clean all brake tube to HCU connections.
Brake Tube Fittings:
8. Remove the primary and secondary brake tubes coming from the master cylinder, at the HCU using a crow foot wrench.
9. Remove the chassis brake tubes at the HCU, using a crow foot wrench.
CAUTION: Do not apply a 12-volt power source to any terminals of the 24-way HCU connector when disconnected from the CAB.
10. Disconnect the 24-way wiring harness connector from the CAB using the following procedure. Grasp the lock on the 24-way connector, and pull it up from the connector as far as possible. This will unlock and raise the 24-way connector out of the socket on the CAB.
11. Raise vehicle.
12. Remove the left front tire and wheel assembly.
13. Remove fasteners securing the inner fender splash shield in place. Move the splash shield out of the way.
14. Remove the 3 bolts attaching the ICU to the mounting bracket.
15. Remove the ICU from its mounting bracket. Then, remove the ICU from the vehicle by pulling it out around the left side of the mounting bracket, then through the wheel well.
NOTE: To separate the CAB from the HCU, Refer to ICU (INTEGRATED CONTROL UNIT) - DISASSEMBLY.
DISASSEMBLY - ICU
NOTE: To replace the hydraulic control unit (HCU) or the controller antilock brake (CAB) on this vehicle, the entire integrated control unit (ICU) needs to be removed from the vehicle. The CAB can then be separated from the HCU. Do not attempt to replace the CAB with the ICU mounted in the vehicle.
1. Remove the ICU from the vehicle.
2. Disconnect the pump/motor wiring harness from the CAB.
CAB Attaching Bolts:
3. Remove the 4 bolts attaching the CAB to the HCU.
4. Remove the CAB from the HCU.
ASSEMBLY - ICU
1. Install the CAB on the HCU.
2. Install the 4 bolts mounting the CAB to the HCU. Tighten the CAB mounting bolts to a torque of 2 Nm (17 inch lbs.).
3. Plug the pump/motor wiring harness into the CAB.
4. Install the ICU in the vehicle.
INSTALLATION - ICU
1. Install the ICU back in the vehicle and attach it to its mounting bracket. Tighten the 3 ICU mounting bolts to 11 Nm (97 inch lbs.).
2. Reinstall the inner fender splash shield.
3. Reinstall the tire and wheel assembly.
4. Lower the vehicle.
CAUTION: Before installing the 24-way connector in the CAB be sure that the seal is properly installed in the connector.
5. Install the 24-way connector into the socket on the CAB. The connector is installed using the following procedure. Position the 24-way connector in the socket on the CAB and carefully push it onto CAB 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 24-way connector into the socket on the CAB and lock it in the installed position.
6. Install the 4 chassis brake tubes on the HCU. Tighten the chassis brake tubes to 17 Nm (145 inch lbs.).
7. Install the primary and secondary brake lines from the master cylinder on the HCU. Tighten the primary and secondary brake tubes to 17 Nm (145 inch lbs.).
8. Reinstall the transmission controller.
9. Reattach the washer bottle filler neck to the radiator support.
10. Reinstall the speed control servo to its mounting studs and radiator support.
11. Remove brake pedal positioning tool.
12. 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.).
NOTE: The ICU may need to be initialized using the DRBIII scan tool after installation.
13. Bleed the base brakes and the ABS brakes hydraulic system.
14. Road test vehicle to ensure proper operation of the base and ABS systems.