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ICU - Integrated Control Unit: Removal

NOTE: If servicing the controller antilock brake (CAB) only, the CAB can be serviced with the ICU mounted in the vehicle. (Refer to CONTROLLER ANTILOCK BRAKE ).
NOTE: Before proceeding, (Refer to WARNING inDISC & DRUM ) and CAUTION  .
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.
  1. With the engine not running, pump the brake pedal 4-5 strokes until the pedal feel is firm.
  2. Unclip the air cleaner cover (two clips) and move the cover aside.
  3. Remove the air cleaner housing by pulling straight up.
  4. Disconnect the negative (ground) cable from the battery and isolate the cable.
  5. Unlatch the power distribution center, lift it up, and move it to the side.
  6. Remove the vehicle wiring harness connector from brake fluid level switch in master cylinder brake fluid reservoir (Fig 1 ).
    Fig 1: Identifying Master Cylinder & Level Switch
    G03526997Courtesy of DAIMLERCHRYSLER CORP.
  7. 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.
  8. 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.
  9. Disconnect and remove the primary and secondary brake tubes coming from the master cylinder at the ICU hydraulic control unit (HCU) (Fig 2 ).
    Fig 2: Identifying Primary & Secondary Brake Tubes
    G03526998Courtesy of DAIMLERCHRYSLER CORP.
  10. 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.
  11. Remove the two nuts attaching the master cylinder to the power brake booster.
  12. Slide the master cylinder straight out of the power brake booster.
  13. Disconnect the brake tubes going to each individual brake at the HCU (Fig 3 ).
  14. 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.
    Fig 3: Identifying ICU Connections
    G03526999Courtesy of DAIMLERCHRYSLER CORP.
  15. Remove the 3 bolts attaching the ICU to its mounting bracket (Fig 3 ).
  16. Remove the ICU from the vehicle.
  17. To separate the CAB from the HCU, (Refer to DISASSEMBLY - ICU  ).
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