Removal and Installation
INTEGRATED CONTROL UNIT (ICU)REMOVAL
1. Remove the remote ground cable from the ground stud on the left strut tower.
2. Correctly isolate remote ground cable when servicing vehicle by installing the ground cable insulator on the strut tower ground stud. This will prevent accidental grounding of the remote ground cable.
3. Using a brake pedal positioning tool (Fig. 22), 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 air cleaner housing.
5. Clean any debris away from the fittings on top of the ICU.
6. Remove the two brake tubes coming from the primary and secondary master cylinder ports at the ICU (Fig. 23).
7. Remove the four chassis brake tubes going to each brake, mounted in-line across the top of the junction block (Fig. 23).
8. Disconnect the 24-way wiring harness connector from the CAB (Fig. 23) 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 connector out of the socket on the CAB.
9. Remove the three bolts fastening the ICU to its mounting bracket (Fig. 24). Remove the ICU from the vehicle.
10. To separate the HCU from the CAB.
INSTALLATION
1. Install the ICU back in the vehicle on its mounting bracket (Fig. 24).
2. Install isolators, washers and attaching bolts, mounting the ICU to its mounting bracket. Tighten the 3 HCU mounting bolts to a torque of 11 Nm (97 inch lbs.).
CAUTION: Before installing the 24-way connector in the CAB be sure that the seal is properly installed in the connector.
3. Install the 24-way connector into the socket on the CAB (Fig. 23). The connector is installed using the following procedure. Position the 24-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 connector into the socket on the CAB and lock it in the installed position.
4. Install the four chassis brake tubes (going to each brake) to the top of the ICU (Fig. 23). Tighten the tube fittings to 17 Nm (145 inch lbs.) torque with the aid of a crow foot wrench.
5. Install the two brake tubes coming from the primary and secondary master cylinder ports to the top corners of the ICU (Fig. 23). Tighten the tube fittings to 17 Nm (145 inch lbs.) torque with the aid of a crow foot wrench.
6. Install the air cleaner housing. .
7. Remove the brake pedal holding tool.
8. Install the remote ground cable onto the ground stud located on left shock tower.
9. Bleed the base brakes and the ABS brakes hydraulic system.
10. Road test vehicle to ensure proper operation of the base and ABS systems.