ICU (Integrated Control Unit): Removal
WARNING:
Dust and dirt accumulating on brake parts during normal use may contain asbestos fibers from production or aftermarket linings. Breathing excessive concentrations of asbestos fibers can cause serious bodily harm. Exercise care when servicing brake parts. DO NOT clean brake parts with compressed air or by dry bushing. Use a vacuum cleaner specifically designed for the removal of asbestos from brake components. If a suitable vacuum cleaner is not available, cleaning should be done with a water dampened cloth. DO NOT sand, or grind brake lining unless equipment used is designed to contain dust residue. Dispose of all residue containing asbestos fibers in sealed bags or containers to minimize exposure to yourself and others. Follow practices prescribed by the occupational safety and health administration and the environmental protection agency for the handling, processing, and disposition of dust or debris that may contain asbestos fibers.
CAUTION:
Many components of the ABS System are not serviceable and must be replaced as an assembly. Do not disassemble any component which is not designed to be serviced.
CAUTION:
Only the recommended jacking or hoisting positions for this vehicle are to be used whenever it is necessary to lift a vehicle. Failure to raise a vehicle from the recommended locations could result in lifting a vehicle by the hydraulic control unit mounting bracket. Lifting a vehicle by the hydraulic control unit mounting bracket will result in damage to the mounting bracket and the hydraulic control unit.
CAUTION:
Brake fluid will damage painted surfaces. If brake fluid is spilled on any painted surface, wash off with water immediately.
CAUTION:
The vacuum in the power brake booster must be pumped down before removing the master cylinder to prevent the booster from sucking in any contamination. This can be done by pumping the brake pedal while the engine is not running until a firm brake pedal is achieved.
- With the engine not running, pump the brake pedal 4-5 strokes until the pedal feel is firm.
- Unclip the air cleaner cover (two clips) and move the cover aside.
- Remove the air cleaner housing by pulling straight up.
- Disconnect the negative (ground) cable from the battery and isolate the cable.
- Unlatch the power distribution center, lift it up, and move it to the side.
- Remove the vehicle wiring harness connector from brake fluid level switch in master cylinder brake fluid reservoir (Fig 1 ).
- Tag the brake tubes coming from the master cylinder as primary and secondary (Fig 2 ). This is done to avoid mix-up once the tubes are removed from the vehicle.
- Disconnect the two brake tubes from the master cylinder primary and secondary ports (Fig 2 ). Install plugs at all of the open brake tube outlets on the master cylinder.
- Disconnect and remove the primary and secondary brake tubes coming from the master cylinder at the ICU hydraulic control unit (HCU) (Fig 2 ).
- Clean the area around where the master cylinder attaches to the power brake booster using a suitable brake cleaner such as Mopar(R) Brake Parts Cleaner or equivalent.
- Remove the two nuts attaching the master cylinder to the power brake booster.
- Slide the master cylinder straight out of the power brake booster.
- Disconnect the brake tubes going to each individual brake at the HCU (Fig 3 ).
- Disconnect the 24-way connector from the controller antilock brake (CAB) mounted on the integrated control unit (ICU) and move it out of the way (Fig 3 ). The connector is disconnected by pulling outward on the connector lock. This will unlock and raise the 24-way connector out of the socket on the CAB.
- Remove the 3 bolts attaching the ICU to its mounting bracket (Fig 3 ).
- Remove the ICU from the vehicle.
- To separate the CAB from the HCU, (Refer to ICU (INTEGRATED CONTROL UNIT) - DISASSEMBLY ).