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ICU - Integrated Control Unit: Installation

  1. Install the ICU onto its mounting bracket.
  2. Install the 3 bolts attaching the ICU to the mounting bracket (Figure ). Tighten the 3 mounting bolts to a torque of 11 N.m (97 in. lbs.)
    CAUTION: Before installing the 24-way connector in the CAB, be sure the seal is properly installed in the connector.
  3. Install the 24-way connector into the socket of the CAB as follows:
    • Position the 24-way connector in the socket of the CAB and carefully push it down as far as possible (Figure ).
    • When the connector is fully seated into the CAB socket, push the connector lock inward. This pulls the connector into the socket of the CAB and locks it in the installed position.
  4. Install the four brake tubes going to the brakes into their respective outlet ports on the ICU HCU (Figure ). Using a crow foot on a torque wrench, tighten the four brake tube nuts to a torque of 17 N.m (145 in. lbs.).
  5. Wipe the face of the power brake booster clean where the master cylinder seal comes in contact when it's installed. Do not get any cleaner or debris inside the booster.
  6. Position the master cylinder on the studs of the power brake booster, aligning the push rod of the power brake booster with master cylinder piston push rod. Carefully push the master cylinder onto the studs until it contacts the face of the booster.
  7. Install the two master cylinder mounting nuts and tighten each to a torque of 18 N.m (160 in. lbs.).
    NOTE: When installing the brake tubes from the master cylinder on the HCU, the brake tube with the small tube nut is to be installed in the forward-most port on the HCU with the small end going toward the master cylinder secondary port.
  8. Install the primary and secondary brake tubes from the master cylinder onto the HCU (Figure ). Do not completely tighten the primary and secondary tubes at this time.
  9. Connect the two brake tubes to the master cylinder primary and secondary ports (Figure ).
  10. Using a crow foot on a torque wrench, tighten the primary and secondary brake tube nuts at both the master cylinder and HCU to a torque of 17 N.m (145 in. lbs.)
  11. Connect the brake fluid level switch wiring connector.
  12. Install the power distribution center.
  13. Connect the negative (ground) cable on the battery.
  14. Install the air cleaner housing.
  15. Install the air cleaner cover.
  16. Hook up the DRBIII(R) to initialize the new CAB.
  17. Fill the master cylinder to the proper fill level and bleed the base and ABS hydraulic systems. (Refer to BLEEDING BRAKE SYSTEM and STANDARD PROCEDURE  ).
  18. Road test the vehicle to ensure proper operation of the base and antilock brake systems.
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