Breeze, Cirrus, Sebring Convertible and Sedan, Stratus Sedan, 1999-2005

Hydraulic Control Unit

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For 2001-05 models the Hydraulic Control Unit (HCU) and the Controller Antilock Brake (CAB) used with this antilock brake system are combined (integrated) into one unit, which is called the Integrated Control Unit (ICU). The ICU is located below the air cleaner housing on the lower radiator support.

Removal & Installation




NOTE
Before proceeding, review SERVICE WARNINGS AND CAUTIONS at the beginning of this section.

  1. Remove the remote ground cable from the ground stud on the left strut tower.
  2.  
  3. Correctly isolate remote ground cable when servicing vehicle by installing the ground cable insulator on the strut tower ground stud and installing the nut on the stud. This will prevent accidental grounding of the remote ground cable.
  4.  
  5. Using a brake pedal positioning tool depress brake pedal past its first 1 inch of travel and hold in this position. This will isolate the master cylinder reservoir from the brake hydraulic system, not allowing the brake fluid to drain out of the reservoir.
  6.  
  7. Raise vehicle on jackstands or centered on a hoist.
  8.  
  9. Remove the splash shield from the right side of the engine compartment.

    Click image to see an enlarged view

    Fig. Splash shield (1)

  10.  
  11. Remove the entire exhaust system from the vehicle as a complete assembly using the following steps.
    1. Disconnect the oxygen sensor wiring harnesses from the vehicle wiring harness.
    2.  
    3. Remove the ground strap between the frame and muffler at the muffler bracket.
    4.  
    5. Remove attaching bolts from exhaust pipe at exhaust manifold on engine.

      Click image to see an enlarged view

      Fig. Nuts (1), seal ring (2), nuts (3) 24 ft. lbs (32 Nm), gasket (4), shoulder bolt (5) 21 ft. lbs (28 Nm) and spring (6)

    6.  
    7. Remove all exhaust system support/isolators from the vehicle's exhaust system. Remove support/isolators from brackets on exhaust system components and leave attached to body of vehicle.

      Click image to see an enlarged view

      Fig. Rear muffler support isolators (1), front muffler support isolator (2) and resonator support isolators (3)

    8.  
    9. Lower exhaust system as a complete assembly away from the underbody of the vehicle.
    10.  

  12.  
  13. Remove the heat shield for the HCU from the HCU mounting bracket.

    Click image to see an enlarged view

    Fig. Front suspension crossmember (1), HCU (2), bolt (3) and heat shield (4)

  14.  
  15. Using Brake Parts Cleaner thoroughly clean all surfaces of the HCU. Also, thoroughly clean all brake tube to HCU connections.
  16.  
  17. Remove the 4 chassis brake tubes from the outlet ports on the HCU.

    Click image to see an enlarged view

    Fig. HCU (1), halfshaft (2) and chassis brake tubes (3)

  18.  
  19. Remove the primary and secondary brake tubes coming from the master cylinder from the HCU inlet ports.

    Click image to see an enlarged view

    Fig. HCU (1) and master cylinder brake tubes (2)

  20.  
  21. Remove the bolt attaching the front leg of the HCU mounting bracket to the front suspension crossmember.

    Click image to see an enlarged view

    Fig. HCU mounting bracket (1), HCU (2), halfshaft (3), bolt (4) and front suspension crossmember (5)

  22.  
  23. Remove the 2 bolts attaching the back legs of the HCU mounting bracket to the front suspension crossmember.

    Click image to see an enlarged view

    Fig. Front suspension crossmember (1), mounting bolt (2), mounting bolt (3), HCU mounting bracket (4) and stabilizer bar (5)

  24.  
  25. Remove the bolt attaching the side of the HCU to the mounting bracket.
  26.  
  27. Remove the 2 bolts attaching the top of the HCU to the mounting bracket.
    WARNING
    Do not apply a 12 - volt power source to any terminals of the 25-way CAB connector while disconnected from the CAB.

  28.  
  29. Disconnect the 25-way wiring harness connector from the CAB using the following procedure. Grasp the lock on the 25-way connector and pull it out from the connector as far as possible. This will unlock and raise the 25-way connector out of the socket on the CAB.
  30.  
  31. Remove the ICU from its mounting bracket. Then remove the ICU from the vehicle by pulling it out through the area between the right halfshaft and frame rail.
  32.  

To install:

  1. Install the ICU back in the vehicle and on its mounting bracket using the reverse order of its removal.
  2.  
  3. Install the isolators, washers and attaching bolts, mounting the ICU to its mounting bracket.
  4.  
  5. Tighten the 3 HCU mounting bolts to 97 inch lbs. (11 Nm)
    WARNING
    Before installing the 25-way connector in the CAB be sure that the seal is properly installed in the connector.

  6.  
  7. Install the 25-way connector into the socket on the CAB. The connector is installed using the following procedure. Position the 25-way connector in the socket on the CAB and carefully push it down as far as it will go. When connector is fully seated into the CAB socket push in the connector lock as far as it will go. This will pull the 25-way connector into the socket on the CAB and lock it in the installed position.
  8.  
  9. Install the 2 bolts attaching the back legs of the HCU mounting bracket to the front suspension crossmember.

    Click image to see an enlarged view

    Fig. Front suspension crossmember (1), mounting bolt (2), mounting bolt (3), HCU mounting bracket (4) and stabilizer bar (5)

  10.  
  11. Install the bolt attaching the front leg of the HCU mounting bracket to the front suspension crossmember.

    Click image to see an enlarged view

    Fig. HCU mounting bracket (1), HCU (2), halfshaft (3), bolt (4) and front suspension crossmember (5)

  12.  
  13. Tighten the 3 bolts mounting the HCU mounting to the front suspension crossmember to 21 ft. lbs. (28 Nm)
  14.  
  15. Install the primary and secondary brake tubes coming from the master cylinder in the HCU inlet ports.

    Click image to see an enlarged view

    Fig. HCU (1) and master cylinder brake tubes (2)

  16.  
  17. Install the 4 chassis brake tubes in the outlet ports on the HCU.

    Click image to see an enlarged view

    Fig. 1 - HCU (1), halfshaft (2) and chassis brake tubes (3)

  18.  
  19. Using a crow foot and tighten all of the brake tube nuts to 145 inch lbs. (17 Nm).
  20.  
  21. Install the HCU heat shield on the HCU mounting bracket. Install and securely tighten the attaching bolt.

    Click image to see an enlarged view

    Fig. Front suspension crossmember (1), HCU (2), bolt (3) and heat shield (4)

  22.  
  23. Install the exhaust system in vehicle using the reverse steps of its removal.
  24.  
  25. Install the right side engine compartment splash shield back on the vehicle.

    Click image to see an enlarged view

    Fig. Splash shield (1)

  26.  
  27. Lower vehicle.
  28.  
  29. Remove the brake pedal holding tool.
  30.  
  31. Install the remote ground cable onto the ground stud located on left shock tower. Install the remote ground cable attaching nut and tighten to 21 ft. lbs. (28 Nm)
  32.  
  33. Bleed the base brakes and the ABS brakes hydraulic system. Refer to the Bleeding ABS System in this section of the manual for the proper bleeding procedure.
  34.  
  35. Road test vehicle to ensure proper operation of the base and ABS systems.
  36.  

  1. Remove the remote ground cable from the ground stud on the left strut tower.
  2.  
  3. Correctly isolate remote ground cable when servicing vehicle by installing the ground cable insulator on the strut tower ground stud. This will prevent accidental grounding of the remote ground cable.
  4.  
  5. Using a brake pedal positioning tool, depress brake pedal past it-s first one inch of travel and hold in this position. This will isolate the master cylinder reservoir from the brake hydraulic system, not allowing the brake fluid to drain out of the reservoir.
  6.  
  7. Remove the air cleaner housing.
  8.  
  9. Clean any debris away from the fittings on top of the ICU.
  10.  
  11. Remove the two brake tubes coming from the primary and secondary master cylinder ports at the ICU.

    Click image to see an enlarged view

    Fig. Primary brake tube (1), secondary brake tube (2), left front chassis brake tube (3) and ICU (4)

  12.  
  13. Remove the left front chassis brake tube at the ICU.
  14.  
  15. Remove the right front chassis brake tube at the ICU.

    Click image to see an enlarged view

    Fig. Routing clips (1), right front chassis brake tube (2) and ICU (3)

  16.  
  17. Remove the rear chassis brake tubes at the ICU.

    Click image to see an enlarged view

    Fig. ICU (1), left front chassis brake tube (2) and right front chassis brake tube (3)

  18.  
  19. Raise and support the vehicle.
  20.  
  21. Disconnect the 47-way connector from the antilock brake module (ABM) by depressing the tabs on each side of the connector cover, then pulling outward and upward on the lower half of the cover until it locks into position pointing straight outward.

    Click image to see an enlarged view

    Fig. ABM connector release tabs

    1. The connector can then be pulled straight outward off the ABM.
    2.  

  22.  
  23. Remove the three screws fastening the ICU to the lower radiator support.
  24.  
  25. Remove the ICU from the vehicle.

    Click image to see an enlarged view

    Fig. ICU (1), upper mounting screw (2), lower radiator support (3) and lower mounting screw (4)

  26.  

To install:

  1. Install the ICU with bracket in position on lower radiator support.

    Click image to see an enlarged view

    Fig. ICU (1), upper mounting screw (2), lower radiator support (3) and lower mounting screw (4)

  2.  
  3. Install the two upper mounting screws and one lower mounting screw. Tighten the three ICU mounting screws to 21 ft. lbs. (28 Nm).
    WARNING
    Before installing the 47-way connector in the ABM be sure that the seal is properly installed.

  4.  
  5. Install the 47-way wiring connector into the socket of the ABM and close the cover, locking the connector in place.
  6.  
  7. Lower the vehicle.
  8.  
  9. Install the rear chassis brake tubes at the ICU. Using crowsfoot wrench tighten the tube nuts to 145 inch lbs. (17 Nm).

    Click image to see an enlarged view

    Fig. ICU (1), left front chassis brake tube (2) and right front chassis brake tube (3)

  10.  
  11. Install the right front chassis brake tube at the ICU. Using crowsfoot wrench tighten the tube nuts to 145 inch lbs. (17 Nm).

    Click image to see an enlarged view

    Fig. Routing clips (1), right front chassis brake tube (2) and ICU (3)

  12.  
  13. Install the left front chassis brake tube at the ICU. Using crowsfoot wrench tighten the tube nuts to 145 inch lbs. (17 Nm).

    Click image to see an enlarged view

    Fig. Primary brake tube (1), secondary brake tube (2), left front chassis brake tube (3) and ICU (4)

  14.  
  15. Install the two brake tubes coming from the primary and secondary master cylinder ports at the ICU. Using crowsfoot wrench tighten the tube nuts to 145 inch lbs. (17 Nm).
  16.  
  17. Install the air cleaner housing.
  18.  
  19. Remove the brake pedal holding tool.
  20.  
  21. Install the remote ground cable onto the ground stud located on left shock tower.
  22.  
  23. Bleed the base brakes and the ABS brakes hydraulic system. Refer to brake bleeding procedure in this section.
  24.  
  25. Road test vehicle to ensure proper operation of the base and ABS systems.
  26.  

Integrated Control Unit (HCU And Cab)
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect battery negative cable from remote negative terminal on shock tower and properly isolate to prevent accidental reconnection.
  4.  
  5. Using a brake pedal positioning tool to depress the brake pedal
    NOTE
    This will isolate the master cylinder reservoir from the brake hydraulic system, not allowing the brake fluid to drain out of the reservoir.

  6.  
  7. Raise vehicle on jackstands or centered on a hoist.
  8.  
  9. Remove or disconnect the following:

    Splash shield from the right side of the engine compartment
     

  10.  
  11. Remove entire exhaust system from the vehicle as a complete assembly using the following steps.
    1. Disconnect the oxygen sensor wiring harnesses from the vehicle wiring harness.

      Ground strap between the frame and muffler at the muffler bracket.
       
      Attaching bolts from exhaust pipe at exhaust manifold on
       
      Exhaust system support/isolators from the vehicle's exhaust system
       
      Support isolators from brackets on exhaust system components and leave attached to body of vehicle
       

    2.  

  12.  
  13. Lower exhaust system as a complete assembly away from the underbody of the vehicle.

    Heat shield for the HCU from the HCU mounting bracket
     

  14.  
  15. Thoroughly clean all surfaces of the HCU and the electrical connections with brake parts cleaner.
    WARNING
    Do not apply a 12 volt power source to any terminals of the HCU connector when disconnected from the CAB.



    4 chassis brake tubes from the outlet ports on the HCU
     
    Primary and secondary brake tubes coming from the master cylinder from the HCU inlet ports
     
    Bolt attaching the front leg of the HCU mounting bracket to the front suspension crossmember
     
    2 bolts attaching the back legs of the HCU mounting bracket to the front suspension crossmember
     
    Bolt attaching the side of the HCU to the mounting bracket
     
    2 bolts attaching the top of the HCU to the mounting bracket
     

  16.  
  17. Disconnect the 25 way wiring harness connector from the CAB using the following procedure.
    1. Grasp the lock on the 25 way connector and pull it out from the connector as far as possible.
      NOTE
      This will unlock and raise the 25 way connector out of the socket on the CAB

    2.  
    3. Remove the ICU from its mounting bracket.
    4.  
    5. Remove the ICU from the vehicle by pulling it out through the area between the right drive shaft and frame rail.
    6.  

  18.  

To install:

  1. Install ICU back in the vehicle and on its mounting bracket using the reverse order of its removal.
  2.  
  3. Install the ICU to its mounting bracket and torque the bolts to 97 inch lbs. (11 Nm)
    1. Install isolators, washers and attaching bolts when mounting the ICU to its bracket.

      Before installing the 25 way connector in the CAB be sure that the seal is properly installed in the connector.
       

    2.  

  4.  
  5. Install the 25 way connector into the socket on the CAB. The connector is installed using the following procedure:
    1. Position the 25 way connector in the socket on the CAB and carefully push it down as far as it will go.
    2.  
    3. When connector is fully seated into the CAB socket push in the connector lock as far as it will go.
    4.  

  6.  
  7. Install or connect the following:
    NOTE
    You will have to use a crow foot wrench.



    2 bolts attaching the back legs of the HCU mounting bracket to the front suspension crossmember
     
    Bolt attaching the front leg of the HCU mounting bracket to the front suspension crossmember and torque the bolts to 250 inch lbs. (28 Nm)
     
    Primary and secondary brake tubes coming from the master cylinder in the HCU inlet ports Install the 4 chassis brake tubes in the outlet ports on the HCU and torque the tube nuts to 145 inch lbs. (17 Nm)
     



    HCU heat shield mounting bracket and securely tighten the bolt.
     
    Exhaust system in vehicle using the reverse steps of its removal.
     
    Right side engine compartment splash shield
     

  8.  
  9. Lower vehicle.
  10.  
  11. Remove brake pedal holding tool.
  12.  
  13. Install the remote ground cable onto the ground stud located on left shock tower
  14.  
  15. Install the remote ground cable attaching and torque the nut to 250 inch lbs. (28 Nm)
  16.  
  17. Bleed the base brakes and the ABS brakes hydraulic system.
  18.  
  19. Road test vehicle to ensure proper operation of the base and ABS systems.
  20.  

 
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