Installation

1. Install the Integrated Control Unit (ICU) on the mounting bracket.

Hydraulic Control Unit Mounting Bracket:

2. Install the 3 bolts attaching the Hydraulic Control Unit (HCU) to the mounting bracket.
3. Tighten the 3 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.

Unlocked CAB 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.

Chassis Brake Tube Connections To HCU:

5. Install the 4 chassis brake tubes into the outlet ports on the HCU.

Torquing Chassis Tube Nuts At HCU:

6. Using a crow foot tighten the 4 chassis brake tube nuts to a torque of 17 Nm (145 inch lbs.).

NOTE: When installing the master cylinder brake tubes on the HCU, the brake tube with the small tube nut is to be installed in the front inlet port of the HCU. This is the port on the HCU that is toward the front of the vehicle. Also, when installing the brake tubes correctly position them for installation into master cylinder.

Primary And Secondary Brake Tubes From Master Cylinder To HCU:

7. Install the primary and secondary brake tubes from the master cylinder onto the HCU.
8. Using a crow foot as shown -- Step 6 tighten the 2 chassis brake tube nuts to a torque of 17 Nm (145 inch lbs.).

Removing Vacuum Seal From Vacuum Booster:

9. Remove vacuum seal located in the front of the power brake vacuum booster. Vacuum seal is removed by carefully inserting a small screw driver between the push rod of the power brake vacuum booster and vacuum seal and pry seal out of power brake vacuum booster. Do not attempt to pry seal out oil master cylinder by inserting a tool between seal and power brake vacuum booster.
10. Remove old vacuum seal from master cylinder, if the vacuum seal came out of power brake vacuum booster when master cylinder was removed.

CAUTION: When replacing the master cylinder on a vehicle equipped with ABS, a NEW vacuum seal MUST be installed in the power brake vacuum booster. Use only the procedure detailed below for installing vacuum seal into power brake vacuum booster. Be sure old vacuum seal is removed from power brake vacuum booster before attempting to install new seal.

CAUTION: When lubricating master cylinder push rod, use only Mopar Silicone Dielectric Compound. Using any other type of grease or lubricant on the push rod, will not provide adequate long term lubrication of the push rod.

Lubricating Master Cylinder Push Rod:

11. Lubricate master cylinder push rod as indicated only using Mopar Dielectric Grease And No Substitutes. Refer to the Mopar Chemicals Catalog to obtain the required lubricant.

Fig 19 Type 3 Vacuum Seal Installation. Neon Models Equipped With ABS:

Fig 20 Type 3 Vacuum Seal Seating. Neon Models Equipped With ABS:

12. Install vacuum seal on master cylinder push rod as shown with notches on vacuum seal pointing toward master cylinder housing. Then slide vacuum seal onto master push rod until seal is seated against master cylinder housing before installing master cylinder on power brake vacuum booster.

CAUTION: Be sure old vacuum seal is removed from power brake vacuum booster before attempting to install master cylinder and NEW vacuum seal.

13. Position master cylinder on studs of vacuum booster aligning push rod on vacuum booster with master cylinder push rod.

Master Cylinder Mounting:

14. Install the 2 master cylinder to power brake unit mounting nuts. Tighten the mounting nuts to a torque of 28 Nm (250 inch lbs.) torque.

ICU Mounting Location:

15. Connect brake tubes to master cylinder primary and secondary ports. Torque all tube nuts to 17 Nm (145 inch lbs.) torque.

Torquing Brake Tube Nuts At Master Cylinder:

16. Using a crow foot tighten the brake tube nuts at the master cylinder to a torque of 17 Nm (145 inch lbs.).
17. Install the wiring harness connector on the master cylinder reservoir fluid level switch.

Wiring Harness Connection To Speed Control Servo:

18. Install the wiring harness connector on the speed control servo. Then install the routing clip for the speed control servo wiring harness on the speed control servo mounting bracket.
Install speed control servo mounting bracket on body.

Speed Control Servo Bracket Mounting:

19. Install and securely tighten the 2 bolts mounting the bracket for the speed control servo to the body.
20. Install the vacuum supply hose on the speed control servo.

PDC Attachment To Thermogaurd:

21. Install the Power Distribution Center (PDC) on the battery thermogaurd. PDC is install by pushing straight down on it until the two retaining clips holding it to the thermogaurd are latched to the thermogaurd.
22. Connect the negative (ground) cable on the battery.
23. Bleed the base brakes and the ABS brakes hydraulic systems.
24. Fill the master cylinder to the proper fill level.
25. Road test vehicle to ensure proper operation of the base and ABS brake systems.