Dodge Neon / Neon SRT-4. Manual — part 53
REMOVAL - ICU
NOTE: If servicing the controller antilock brake
(CAB) only, the CAB can be serviced with the ICU
mounted in the vehicle. (Refer to 8 - ELECTRICAL/
ELECTRONIC CONTROL MODULES/CONTROLLER
ANTILOCK BRAKE - REMOVAL)
NOTE: Before proceeding, (Refer to 5 - BRAKES -
WARNING).
(1) Using a brake pedal holder, depress the brake
pedal past its first one inch of travel and hold it in
this position (Fig. 16). This will isolate the master
cylinder from the brake hydraulic system and will
not allow the brake fluid to drain out of the master
cylinder reservoir.
(2) Disconnect negative (ground) cable from the
battery and isolate the cable.
(3) Disconnect the positive cable from the battery,
then remove the battery from the battery tray. There
is one nut securing the clamp on the backside of the
battery holding it in place.
(4) Remove the one nut and one bolt securing the
air cleaner box in place, then disconnect the wiring
harness connector at the air inlet sensor.
(5) Lift the air cleaner box upward enough to clear
its grommeted alignment post (Fig. 17), then move
the air cleaner box forward just enough to access the
battery tray mounting bolts.
(6) Remove the 2 bolts, then the 2 nuts mounting
the battery tray to its bracket (Fig. 17). Remove the
battery tray.
(7) Disconnect the primary and secondary brake
tubes from the master cylinder (Fig. 18). Install
plugs in the master cylinder outlet ports.
(8) Disconnect the 24-way connector from the con-
troller antilock brake (CAB) mounted on the inte-
grated control unit (ICU) and move it out of the way.
The connector is disconnected by pulling outward on
the connector lock (Fig. 19). This will unlock and
raise the 24-way connector out of the socket on the
CAB.
(9) Tag the brake tubes coming from the master
cylinder as primary and secondary (Fig. 18). This is
Fig. 14 Integrated Control Unit (ICU)
1 - PUMP/MOTOR
2 - HCU
3 - PUMP/MOTOR WIRING CONNECTOR
4 - CAB
Fig. 15 Master Cylinder And ICU
1 - PRIMARY BRAKE TUBE
2 - MASTER CYLINDER
3 - SECONDARY BRAKE TUBE
4 - ABS ICU
Fig. 16 Brake Pedal Holder
1 - CLUTCH PEDAL (IF EQUIPPED WITH MANUAL TRANSAXLE)
2 - THROTTLE PEDAL
3 - BRAKE PEDAL HOLDING TOOL
4 - STEERING WHEEL
5 - DRIVER’S SEAT
6 - BRAKE PEDAL
5 - 94
BRAKES - ABS
PL/SRT-4
ICU - INTEGRATED CONTROL UNIT (Continued)
done to avoid mix-up once the tubes are removed
from the vehicle.
(10) Disconnect and remove the primary and sec-
ondary brake tubes coming from the master cylinder
at the ICU hydraulic control unit (HCU) (Fig. 18).
(11) Disconnect the brake tubes going to each indi-
vidual brake at the HCU (Fig. 18).
(12) Remove the 3 bolts attaching the ICU to its
mounting bracket. (Fig. 20).
(13) Remove the ICU from the vehicle.
(14) If the CAB and HCU must be separated,
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
ICU (INTEGRATED CONTROL UNIT) - DISASSEM-
BLY).
Fig. 17 Battery Tray Mounting
1 - BATTERY TRAY MOUNTING NUTS
2 - BATTERY TRAY MOUNTING BOLTS
3 - AIR CLEANER BOX POST
Fig. 18 Brake Tube Locations
1 - PRIMARY BRAKE TUBE
2 - SECONDARY BRAKE TUBE
3 - BRAKE TUBES FROM MASTER CYLINDER
4 - BRAKE TUBES TO BRAKES
Fig. 19 Connector Lock Pulled Outward
1 - MASTER CYLINDER
2 - 24–WAY CONNECTOR
3 - CAB
4 - CONNECTOR LOCK PULLED OUTWARD
5 - ICU
Fig. 20 ICU Mounting Bolts
1 - ICU
2 - ICU MOUNTING BOLTS
PL/SRT-4
BRAKES - ABS
5 - 95
ICU - INTEGRATED CONTROL UNIT (Continued)
DISASSEMBLY - ICU
(1) Disconnect the pump/motor wiring harness
from the CAB (Fig. 21).
(2) Remove the 4 bolts attaching the CAB to the
HCU (Fig. 22).
(3) Remove the CAB from the HCU (Fig. 23).
ASSEMBLY - ICU
(1) Install the CAB on the HCU (Fig. 23).
(2) Install the 4 bolts mounting the CAB to the
HCU (Fig. 22). Tighten the CAB mounting bolts to a
torque of 2 N·m (17 in. lbs.).
(3) Plug the pump/motor wiring harness into the
CAB (Fig. 21).
(4) Install the ICU in the vehicle. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ICU
(INTE-
GRATED CONTROL UNIT) - INSTALLATION)
INSTALLATION - ICU
(1) Install the ICU onto its mounting bracket.
(2) Install the 3 bolts attaching the ICU to the
mounting bracket (Fig. 20). Tighten the 3 mounting
bolts to a torque of 11 N·m (97 in. lbs.)
(3) Install the four brake tubes going to the brakes
into their respective outlet ports on the ICU HCU
(Fig. 18). Using a crow foot on a torque wrench,
tighten the four brake tube nuts to a torque of 17
N·m (145 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.
Fig. 21 Integrated Control Unit (ICU)
1 - PUMP/MOTOR
2 - HCU
3 - PUMP/MOTOR WIRING CONNECTOR
4 - CAB
Fig. 22 CAB Attaching Bolts
1 - CAB
2 - HCU VALVE BLOCK
3 - MOUNTING BOLTS
Fig. 23 Remove/Install CAB (Typical)
1 - CAB
2 - HCU VALVES
3 - HCU VALVE BLOCK
5 - 96
BRAKES - ABS
PL/SRT-4
ICU - INTEGRATED CONTROL UNIT (Continued)
(4) Install the primary and secondary brake tubes
from the master cylinder onto the HCU (Fig. 18). Do
not completely tighten the primary and secondary
tubes at this time.
(5) Connect the primary and secondary brake
tubes to the master cylinder ports (Fig. 18).
(6) 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.).
CAUTION: Before installing the 24-way connector in
the CAB, be sure the seal is properly installed in
the connector.
(7) 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 possi-
ble (Fig. 19).
• 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.
(8) Position the battery tray back in place. Install
the two bolts, then the two nuts mounting the bat-
tery tray to its bracket (Fig. 17). Tighten the two
bolts and nuts to a torque of 15 N·m (135 in. lbs.).
(9) Reinstall the air cleaner box onto its grom-
meted alignment post (Fig. 17).
(10) Install the one nut and one bolt securing the
air cleaner box in place, then connect the wiring har-
ness connector at the air inlet sensor.
(11) Install the battery and clamp it in place.
Tighten the hold-down clamp bolt to a torque of 12
N·m (105 in. lbs.).
(12) Connect
the
positive,
then
the
negative
(ground) cable on the battery.
NOTE: The ICU may need to be initialized using the
DRBIII
T
scan tool after ICU installation. Refer to
Appropriate Diagnostic Information.
(13) Bleed the base brakes and ABS hydraulic sys-
tems. (Refer to 5 - BRAKES - ABS - STANDARD
PROCEDURE).
(14) Fill the master cylinder to the proper fill
level.
(15) Road test the vehicle to ensure proper opera-
tion of the base and antilock brake systems.
PL/SRT-4
BRAKES - ABS
5 - 97
ICU - INTEGRATED CONTROL UNIT (Continued)
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