Installation

1. Install the Integrated Control Unit (ICU) on the mounting bracket.
2. Install the 3 bolts attaching the HCU to the mounting bracket. Tighten the 3 mounting bolts to a torque of 11 Nm (97 inch lbs.).

CAUTION: Before installing the 25-way connector in the Controller Antilock Brake(CAB), be sure the seal is properly installed in the connector.

3. Install the 25-way connector into the socket of the CAB as follows:
^ Position the 25-way connector in the socket of the CAB and carefully push it down as far as possible.
^ When the connector is fully seated into the CAB socket, push in the connector lock. This pulls the connector into the socket of the CAB and locks it in the installed position.

Torquing Chassis Tube Nuts At HCU:

4. Install the 4 chassis brake tubes into the outlet ports on the HCU. Using a crow foot on a torque wrench, 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.

5. Install the primary and secondary brake tubes from the master cylinder onto the HCU. Using a crow foot on a torque wrench, tighten the 2 chassis brake tube nuts to a torque of 17 Nm (145 inch lbs.).

CAUTION: The vacuum seal at the front of the power brake booster must be replaced before reinstalling the master cylinder.

Removing Vacuum Seal From Booster:

6. Remove the used vacuum seal located in the front of the power brake vacuum booster. For vacuum seal removal, carefully insert a small screwdriver between the push rod of the power brake booster and the vacuum seal, then pry the seal out of the power brake vacuum booster.

CAUTION: Do not attempt to pry the seal out of the master cylinder by inserting a tool between the outer diameter of the seal and the power brake vacuum booster. Damage to the booster may result.

7. If the old vacuum seal came out of the power brake booster attached to the master cylinder when it was removed, pull the seal off the master cylinder push rod.

CAUTION:
^ When installing the master cylinder on a vehicle, use only the procedure detailed below for installing a new vacuum seal into the power brake vacuum booster. Be sure the old vacuum seal is removed from power brake vacuum booster before attempting to install a new seal.
^ When lubricating master cylinder push rod, use only Mopar Dielectric Grease. Using any other type of grease or lubricant on the push rod will not provide adequate long term lubrication of the push rod.

8. Install a new vacuum seal and the master cylinder into the power brake vacuum booster as follows:

Lubricating Master Cylinder Push Rod:

^ Lubricate the master cylinder push rod as indicated using only Mopar Dielectric Grease.

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

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

^ Install the vacuum seal on master cylinder push rod with the notches on vacuum seal pointing toward the master cylinder housing. Slide the vacuum seal onto master push rod until the seal is seated against the master cylinder housing.
^ Position the master cylinder on the studs of power brake vacuum booster aligning the booster push rod with the master cylinder push rod. Carefully push the master cylinder onto the studs until it contacts the face of the booster.
^ Install the 2 master cylinder mounting nuts. Tighten the mounting nuts to a torque of 28 Nm (250 inch lbs.) torque.

9. Connect the chassis brake tubes to master cylinder primary and secondary ports.
10. Using a crow foot on a torque wrench, tighten the brake tube nuts at the master cylinder to a torque of 17 Nm (145 inch lbs.).
11. Install the wiring harness connector on the master cylinder reservoir fluid level switch.
12. 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.
13. Install the speed control servo mounting bracket on body. Install and securely tighten the 2 bolts mounting the speed control servo bracket to the body.
14. Install the vacuum supply hose on the speed control servo vacuum port.
15. Install the Power Distribution Center (PDC) on the battery thermoguard by pushing straight down on it until the two retaining clips are latched to the thermoguard.
16. Connect the negative (ground) cable on the battery.
17. Bleed the base and Antilock Brake System (ABS) hydraulic systems.
18. Fill the master cylinder to the proper fill level.
19. Road test the vehicle to ensure proper operation of the base and antilock brake systems.