Avenger 2008

Integrated Control Unit

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Removal & Installation



2.4L Engines

Specific to:

Chrysler Sebring 2008-2009

Dodge Avenger 2008-2009

  1. Disconnect and isolate battery negative cable from battery post.
  2.  
  3. Using a brake pedal holding tool, depress the brake pedal past its first 1 inch (25 mm) of travel and hold it in this position. 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 while the lines are disconnected.

    Click image to see an enlarged view

    Fig. Using a brake pedal holding tool, depress the brake pedal

  4.  
  5. Remove the engine appearance cover.
  6.  
  7. Loosen lower and upper mounting nuts, then remove the exhaust heat shield from the dash panel.
  8.  
  9. Pull the brake tube bundle routing clips (with tubes) loose from studs on the dash panel.
  10.  
  11. Remove the primary (4) and secondary (1) brake tubes (from master cylinder) at the hydraulic control unit (7).

    Click image to see an enlarged view

    Fig. Remove the primary (4) and secondary (1) brake tubes (from master cylinder) at the hydraulic control unit (7)

  12.  
  13. Remove the remaining brake tubes (2, 3, 5, 6) at the hydraulic control unit (7).
    NOTE
    Use this figure in the following step to release the ABM harness connector cover. It shows the location of the release tabs.



    Click image to see an enlarged view

    Fig. Use this figure in the following step to release the ABM harness connector cover

  14.  
  15. Disconnect the ABM harness connector from the Antilock Brake Module (ABM). To do so:
    1. Depress the tabs on each side of the connector cover, then
    2.  
    3. Pull outward and upward on the lower half of the cover until it locks into position pointing straight outward (2). The connector can then be pulled straight outward off the ABM (1).

      Click image to see an enlarged view

      Fig. Pull outward and upward on the lower half of the cover until it locks into position pointing straight outward (2)

    4.  

  16.  
  17. Loosen, but do not remove, the two mounting screws (2) attaching the ICU (1) mounting bracket to the body.
  18.  
  19. Lift the ICU and mounting bracket (1) off the mounting screws (2).

    Click image to see an enlarged view

    Fig. Lift the ICU and mounting bracket (1) off the mounting screws (2)

  20.  
  21. Move the brake tubes around as necessary without bending them and remove the ICU with bracket through the opening between the A/C lines and the exhaust manifold.
  22.  

To install:

  1. Install the ICU with bracket (1) through the opening between the A/C lines and the exhaust manifold using the opposite of how it was removed.
  2.  
  3. Place the mounting bracket for the ICU over the mounting screws and hang the assembly in place. Tighten the two mounting screws to 17 ft. lbs. (23 Nm).
    CAUTION
    Before installing the ABM harness connector on the ABM, be sure the seal is properly installed in the connector.

  4.  
  5. Insert the ABM wiring harness connector into the socket of the ABM and close the cover, locking the connector in place.
    CAUTION
    The brake tubes must be routed to the correct ports. Improper routing can lead to degraded or undesirable system performance including external brake fluid leaks.

  6.  
  7. Install the four chassis brake tubes (2, 3, 5, 6) at the ICU hydraulic control unit (7). Tighten the tube nuts to 150 inch lbs. (17 Nm).
  8.  
  9. Install the primary (4) and secondary (1) brake tubes at the ICU hydraulic control unit (7). Tighten the tube nuts to 150 inch lbs. (17 Nm).
  10.  
  11. Push the brake tube bundle routing clips (with tubes) onto the studs on the dash panel.
  12.  
  13. Install the heat shield on the dash panel and tighten the lower and upper mounting nuts.
  14.  
  15. Remove the brake pedal holding tool.
  16.  
  17. Install the engine appearance cover.
  18.  
  19. Connect the battery negative cable to the battery post.
  20.  
  21. Hook up the scan tool to initialize the ABM and perform the following:
    1. Clear any faults.
    2.  
    3. Fill the master cylinder to the proper fill level and bleed the base and ABS hydraulic systems.
    4.  
    5. Check for leaks.
    6.  
    7. Perform the ABS Verification Test and road test the vehicle.
    8.  

  22.  

2.7L & 3.5L Engines

Specific to:

Chrysler Sebring 2008-2009

Dodge Avenger 2008-2009

  1. Disconnect and isolate battery negative cable from battery post.
  2.  
  3. Using a brake pedal holding tool, depress the brake pedal past its first 1 inch (25 mm) of travel and hold it in this position. 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 while the lines are disconnected.

    Click image to see an enlarged view

    Fig. Using a brake pedal holding tool, depress the brake pedal

  4.  
  5. Remove the engine appearance cover.
  6.  
  7. Remove the engine upper intake manifold.
  8.  
  9. Remove the primary (4) and secondary (1) brake tubes (from master cylinder) at the hydraulic control unit (7).

    Click image to see an enlarged view

    Fig. Remove the primary (4) and secondary (1) brake tubes (from master cylinder) at the hydraulic control unit (7)

  10.  
  11. Remove the remaining brake tubes (2, 3, 5, 6) at the hydraulic control unit (7).
  12.  
  13. Pull the brake tube bundle routing clip (with tubes) loose from the stud on the right side of the dash panel.
    NOTE
    Use this figure in the following step to release the ABM harness connector cover. It shows the location of the release tabs.



    Click image to see an enlarged view

    Fig. Use this figure in the following step to release the ABM harness connector cover

  14.  
  15. Disconnect the ABM harness connector from the Antilock Brake Module (ABM). To do so:
    1. Depress the tabs on each side of the connector cover, then
    2.  
    3. Pull outward and upward on the lower half of the cover until it locks into position pointing straight outward (2). The connector can then be pulled straight outward off the ABM (1).

      Click image to see an enlarged view

      Fig. Pull outward and upward on the lower half of the cover until it locks into position pointing straight outward (2)

    4.  

  16.  
  17. Loosen, but do not remove, the two mounting screws (2) attaching the ICU (1) mounting bracket to the body.
  18.  
  19. Lift the ICU and mounting bracket (1) off the mounting screws (2).

    Click image to see an enlarged view

    Fig. Lift the ICU and mounting bracket (1) off the mounting screws (2)

  20.  
  21. Move the brake tubes around as necessary without bending them and remove the ICU with bracket (1) through the opening above the rear cylinder head cover (2).

    Click image to see an enlarged view

    Fig. Remove the ICU with bracket (1) through the opening above the rear cylinder head cover (2)

  22.  

To install:

  1. Install the ICU with bracket through the opening above the rear cylinder head cover following the opposite of how it was removed.
  2.  
  3. Place the mounting bracket for the ICU over the mounting screws and hang the assembly in place. Tighten the two mounting screws to 17 ft. lbs. (23 Nm).
    CAUTION
    Before installing the ABM harness connector on the ABM, be sure the seal is properly installed in the connector.

  4.  
  5. Insert the ABM wiring harness connector into the socket of the ABM and close the cover, locking the connector in place.
    CAUTION
    The brake tubes must be routed to the correct ports. Improper routing can lead to degraded or undesirable system performance including external brake fluid leaks.

  6.  
  7. Install the four chassis brake tubes (2, 3, 5, 6) at the ICU hydraulic control unit (7). Tighten the tube nuts to 150 inch lbs. (17 Nm).
  8.  
  9. Install the primary (4) and secondary (1) brake tubes at the ICU hydraulic control unit (7). Tighten the tube nuts to 150 inch lbs. (17 Nm).
  10.  
  11. Push the brake tube bundle routing clip (with tubes) onto the stud on the right side of the dash panel.
  12.  
  13. Install the engine upper intake manifold.
  14.  
  15. Remove the brake pedal holding tool.
  16.  
  17. Install the engine appearance cover.
  18.  
  19. Connect the battery negative cable to the battery post.
  20.  
  21. Hook up the scan tool to initialize the ABM and perform the following:
    1. Clear any faults.
    2.  
    3. Fill the master cylinder to the proper fill level and bleed the base and ABS hydraulic systems.
    4.  
    5. Check for leaks.
    6.  
    7. Perform the ABS Verification Test and road test the vehicle.
    8.  

  22.  

 
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