Integrated Control Unit (ICU): Installation

Fig 1: ICU Mounting Location

Courtesy of DAIMLERCHRYSLER CORP.

1 - BODY FRAME RAIL

2 - FRONT MOUNTING SCREW

3 - ICU MOUNTING BRACKET

4 - REAR MOUNTING SCREWS

1. Place the ICU and mounting bracket (3) into the engine compartment, inserting the bracket hooks into the hanger holes in the body frame rail (1).
2. Install the front mounting screw (2) attaching the ICU mounting bracket (3) to the body (1). Do not tighten screw at this time. 
3. Raise and support the vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE)
4. Install the two rear mounting screws (4) attaching the ICU mounting bracket (3) to the body (1). Tighten both screws to 23 N.m (200 in. lbs.).
5. Lower the vehicle.
6. Tighten the front mounting screw (2) to 23 N.m (200 in. lbs.).
   Fig 2: Wiring Harness Connector at ABM

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - ABM (PART OF ICU)

   2 - WIRING HARNESS CONNECTOR

   CAUTION: Before installing the ABM harness connector on the ABM, be sure the seal is properly installed in the connector.
7. Insert the ABM harness connector (2) into the socket of the ABM (1) and close the cover, locking the connector in place.
   Fig 3: Chassis Brake Tubes At ICU

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - RIGHT FRONT CHASSIS BRAKE TUBE

   2 - LEFT REAR CHASSIS BRAKE TUBE

   3 - RIGHT REAR CHASSIS BRAKE TUBE

   4 - HCU

8. Connect the right front (1), left rear (2) and right rear (3) chassis brake tubes to their respective outlet ports on the ICU HCU (4). Using a crow foot wrench on a torque wrench, tighten the four tube nuts to 17 N.m (145 in. lbs.).
   Fig 4: LHD Master Cylinder & Primary And Secondary Brake Tubes To ICU

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - MASTER CYLINDER

   2 - HCU

   3 - LEFT FRONT CHASSIS BRAKE TUBE

   4 - SECONDARY BRAKE TUBE

   5 - PRIMARY BRAKE TUBE

9. LHD Vehicle:
   • Connect the left front chassis brake tube (3) at the HCU (2). Using a crow foot wrench on a torque wrench, tighten the tube nut to 17 N.m (145 in. lbs.).
   • Connect the primary (5) and secondary (4) brake tubes coming from the master cylinder (1) at the HCU (2). Using a crow foot wrench on a torque wrench, tighten the tube nuts to 17 N.m (145 in. lbs.).
   Fig 5: RHD Primary & Secondary Brake Tubes To ICU

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - MASTER CYLINDER

   2 - SECONDARY BRAKE TUBE

   3 - PRIMARY BRAKE TUBE

   4 - HCU

   5 - LEFT FRONT CHASSIS BRAKE TUBE

10. RHD Vehicle:
    • Connect the left front chassis brake tube (5) at the HCU (4). Using a crow foot wrench on a torque wrench, tighten the tube nut to 17 N.m (145 in. lbs.).
    • Connect the primary (3) and secondary (2) brake tubes coming from the master cylinder (1) at the HCU (2). Using a crow foot wrench on a torque wrench, tighten the tube nuts to 17 N.m (145 in. lbs.).
    Fig 6: PDC With Bracket Mounting - Non-Turbo Engine

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - MOUNTING BOLTS

    2 - PDC AND MOUNTING BRACKET

11. Non-Turbo Engine - Position the power distribution center and bracket back into place and install the two bolts (1) fastening the power distribution center and mounting bracket (2) in place.
    Fig 7: PDC With Bracket Mounting - Turbo Engine

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - MOUNTING BOLTS

    2 - PDC AND MOUNTING BRACKET

12. Turbo Engine - Position the power distribution center and bracket back into place and install the two bolts (1) fastening the power distribution center and mounting bracket (2) in place.
    Fig 8: Brake Fluid Level Switch

    Courtesy of DAIMLERCHRYSLER CORP.
13. Connect the wiring connector (2) to the brake fluid level switch in the brake fluid reservoir (1).
14. Install the battery. (Refer to ELECTRICAL/BATTERY SYSTEM/BATTERY - INSTALLATION)
15. Install the air cleaner housing. (Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - INSTALLATION) or (Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - INSTALLATION) .
16. Hook up the scan tool to initialize the ABM and perform the following:
    • Clear any faults.
    • Fill the master cylinder to the proper fill level and bleed the base and ABS hydraulic systems. (Refer to BRAKES - ABS - STANDARD PROCEDURE - ANTILOCK BRAKE SYSTEM BLEEDING)  .
    • Perform the ABS Verification Test and road test the vehicle.