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Integrated Control Unit - MK25E: Removal

  1. Disconnect negative (-) battery cable from battery post and isolate.
    2. CAUTION: Vacuum in power brake booster must be pumped down (removed) before removing master cylinder from power brake booster. This is necessary to prevent power brake booster from sucking in any contamination as master cylinder is removed. This can be done simply by pumping brake pedal, with vehicle's engine not running, until a firm feeling brake pedal is achieved.
  2. With engine not running, pump brake pedal until a firm pedal is achieved (4-5 strokes).
  3. Remove nuts fastening coolant recovery bottle in place and reposition bottle with hoses attached out of way. (Refer to COOLING/ENGINE/COOLANT RECOVERY PRESS CONTAINER - REMOVAL)
    4. CAUTION: Before removing master cylinder from power brake vacuum booster, master cylinder and vacuum booster must be thoroughly cleaned. This must be done to prevent dirt particles from falling into power brake vacuum booster.
  4. Thoroughly clean all surfaces of brake fluid reservoir and master cylinder, paying special attention to area where master cylinder attaches to power brake booster. Use only Mopar(R) Brake Parts Cleaner or equivalent.
  5. Disconnect wiring harness connector from brake fluid level switch in master cylinder brake fluid reservoir. See Fig 1.
    Fig 1: Master Cylinder Mounting
    GC0001696Courtesy of DAIMLERCHRYSLER CORP.
    1 - MASTER CYLINDER
    2 - SENSOR WIRING HARNESS CONNECTOR
    3 - BOOSTER
    4 - MOUNTING NUT
  6. Disconnect primary and secondary brake tubes coming from master cylinder at ABS ICU. See Fig 2. Cap off brake tubes and install sealing plugs in open brake tube outlet ports of ICU.
    Fig 2: Primary And Secondary Brake Tubes At ICU
    GC0001695Courtesy of DAIMLERCHRYSLER CORP.
    1 - MASTER CYLINDER
    2 - PRIMARY BRAKE TUBE
    3 - ICU
    4 - SECONDARY BRAKE TUBE
  7. Remove two nuts attaching master cylinder to power brake booster. See Fig 1.
  8. Slide master cylinder straight out of power brake booster and remove. See Fig 1.
  9. Disconnect four Chassis brake tubes at ABS ICU. See Fig 3. Cap off brake tubes and install sealing plugs in open brake tube outlet ports of ICU.
    Fig 3: Chassis Brake Tubes At ICU
    GC0001694Courtesy of DAIMLERCHRYSLER CORP.
    1 - LEFT FRONT CHASSIS BRAKE TUBE
    2 - RIGHT FRONT CHASSIS BRAKE TUBE
    3 - ICU
    4 - LEFT REAR CHASSIS BRAKE TUBE
    5 - RIGHT REAR CHASSIS BRAKE TUBE
  10. Disconnect the 47-way connector from the antilock brake module (ABM) by depressing the tabs on each side of the connector cover. See Fig 4, then pulling outward and upward on the lower half of the cover until it locks into position pointing straight outward. The connector can then be pulled straight outward off the ABM. See Fig 5.
    Fig 4: ABM Connector Release Tabs
    GC0000018Courtesy of DAIMLERCHRYSLER CORP.
    Fig 5: Wiring Harness Connector At ABM
    GC0000017Courtesy of DAIMLERCHRYSLER CORP.
    1 - ABM (PART OF ICU)
    2 - WIRING HARNESS CONNECTOR
  11. Loosen 2 bolts fastening ABS ICU bracket to frame rail. See Fig 6.
    Fig 6: ICU Mounting
    GC0001697Courtesy of DAIMLERCHRYSLER CORP.
    1 - MOUNTING BOLTS
    2 - ICU
  12. Lift ICU off frame rail bolts and remove from vehicle.
  13. If ABM and HCU need to be separated, (Refer to BRAKES/HYDRAULIC/MECHANICAL/ICU (INTEGRATED CONTROL UNIT - DISASSEMBLY) 
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