Chrysler RG Voyager. Manual — part 675
CHANICAL/ICU (INTEGRATED CONTROL UNIT) -
DISASSEMBLY).
DISASSEMBLY
(1) If not equipped with traction control, remove
the three screws attaching the ABM to the HCU (Fig.
39).
(2) If equipped with traction control, remove the
four screws attaching the ABM to the HCU (Fig. 40).
(3) Separate the ABM from the HCU (Fig. 41).
Fig. 37 Chassis Brake Tubes At ICU
1 - RIGHT FRONT CHASSIS BRAKE TUBE
2 - LEFT FRONT CHASSIS BRAKE TUBE
3 - LEFT REAR CHASSIS BRAKE TUBE
4 - RIGHT REAR CHASSIS BRAKE TUBE
5 - ICU
Fig. 38 ICU Mounting Bolt
1 - ICU
2 - MOUNTING BOLT
3 - MOUNTING BRACKET
Fig. 39 ABM Mounting Screws - Without Traction
Control
1 - MOUNTING SCREWS
2 - ABM
Fig. 40 ABM Mounting Screws - With Traction
Control
1 - MOUNTING SCREWS
2 - ABM
RS
BRAKES - ABS
5 - 113
INTEGRATED CONTROL UNIT (ICU) - MK25E (Continued)
ASSEMBLY
(1) Clean any debris off the mating surfaces of the
HCU and ABM.
CAUTION: When installing new O-rings or solenoid
valve stem seals, do not use any type of lubricant.
(2) If the seals on the components are not new,
they must be replaced. Each of the solenoid valve
stem seals must be replaced (Fig. 42); do not reuse
solenoid valve stem seals. The pump/motor con-
nector O-ring should also be replaced if not new (Fig.
43).
(3) Align components and install the ABM on the
HCU (Fig. 41).
(4) If not equipped with traction control, install
the three screws attaching the ABM to the HCU (Fig.
39). Tighten the mounting screws to 2 N·m (17 in.
lbs.) torque.
(5) If equipped with traction control, install the
four screws attaching the ABM to the HCU (Fig. 40).
Tighten the mounting screws to 2 N·m (17 in. lbs.)
torque.
(6) Install the ICU in the vehicle. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ICU
(INTE-
GRATED CONTROL UNIT) - INSTALLATION)
INSTALLATION
(1) Place the ICU in its bracket below the master
cylinder by first inserting the mounting pins on the
bottom of the ICU into the grommets mounted in the
bracket, then install the single mounting bolt on the
side (Fig. 38). Tighten the mounting bolt to 11 N·m
(97 in. lbs.) torque.
(2) Install the four chassis brake tubes into their
correct port locations on the ICU as shown (Fig. 37).
Tighten the tube nuts to a torque of 17 N·m (145 in.
lbs.).
Fig. 41 ABM Assembly To HCU
1 - ABM
2 - HCU
3 - SOLENOID VALVE STEM
Fig. 42 Solenoid Valve Seal
1 - SEAL
2 - SOLENOID VALVE STEM
Fig. 43 Internal Pump Connector O-Ring
1 - O-RING
2 - O-RING MOUNTING GROOVE
5 - 114
BRAKES - ABS
RS
INTEGRATED CONTROL UNIT (ICU) - MK25E (Continued)
CAUTION: Because of the flexible section in the pri-
mary and secondary brake tubes, the brake tubes
must be held in proper orientation when tightened
and torqued. These tubes must not contact each
other or other vehicle components when installed.
Also, after the brake tubes are installed on the ICU,
ensure all spacer clips are reinstalled on the brake
tubes.
(3) Install the primary and secondary brake tubes
into their correct port locations on the ICU (Fig. 36).
Tighten the tube nuts to a torque of 17 N·m (145 in.
lbs.).
(4) Install any routing clips on the brake tubes.
(5) With connector cover completely open (Fig. 35),
install 47-way wiring connector into socket of the
ABM and close cover, locking connector in place.
(6) Install the speed control servo with its mount-
ing nuts.
(7) Connect the wiring harness to the speed con-
trol servo.
(8) Install the battery tray. (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/TRAY - INSTALLATION)
(9) Install the screw securing the coolant filler
neck to the battery tray.
(10) Reconnect the vacuum hose connector at the
tank built into the battery tray.
(11) Install the battery and battery shield. (Refer
to 8 - ELECTRICAL/BATTERY SYSTEM/BATTERY -
INSTALLATION)
(12) Remove the brake pedal holder.
(13) Connect the negative cable on the battery
negative post.
(14) Hook up a scan tool to initialize ABM and
check for any faults.
(15) Fill master cylinder with clean, fresh Mopar
t
Brake Fluid or equivalent, then bleed base brakes
and ABS. (Refer to 5 - BRAKES - STANDARD PRO-
CEDURE)
(16) Road test vehicle to ensure proper operation
of brakes.
RS
BRAKES - ABS
5 - 115
INTEGRATED CONTROL UNIT (ICU) - MK25E (Continued)
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