Chrysler Cirrus/Stratus/Sebring/Avenger/Breeze 1995-1998

Hydraulic Control Unit

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REMOVAL & INSTALLATION



Cirrus, Stratus, Sebring Convertible and Breeze
1995-97 MODELS

See Figures 1 through 6

  1. Disconnect and isolate the negative battery cable.
  2.  
  3. Using a brake pedal positioning tool, or equivalent, depress the brake pedal past the first 1 inch of travel and hold in this position. This will isolate the master cylinder reservoir from the brake hydraulic system, which will prevent the brake fluid from draining out of the reservoir.
  4.  
  5. Raise and support the vehicle safely.
  6.  
  7. Using Brake Parts Cleaner, thoroughly clean all surfaces, brake line fittings and connections to the HCU.
  8.  
  9. Remove the entire exhaust system.
  10.  
  11. Remove the right inner fender splash shield.
  12.  



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Fig. Fig. 1: Brake pedal holding tool installed



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Fig. Fig. 2: Remove the HCU heat shield



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Fig. Fig. 3: Disengage the electrical connections at the HCU and relay box



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Fig. Fig. 4: Disconnect the 2 brake tubes from the master cylinder, as well as the brake tube leading to the left front wheel at the HCU ports



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Fig. Fig. 5: Disconnect the 2 rear brake tubes from the proportioning valves, as well as the right front brake tube from the HCU outlet port



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Fig. Fig. 6: Remove the front HCU-to-mounting bracket bolt, isolator and washer

  1. Remove the HCU heat shield from the mounting bracket.
  2.  
  3. Disengage the 6-way HCU wiring harness connector and the 10-way connector from the relay box on the HCU.
  4.  
  5. Remove the brake tube routing clip from the HCU mounting bracket. Then remove the 2 brake tubes coming from the master cylinder and the brake tube leading to the left front wheel from the HCU ports.
  6.  
  7. Disconnect the 2 rear brake tubes from the proportioning valves and the right front brake tube from the HCU outlet port.
  8.  
  9. Remove the front HCU-to-mounting bracket bolt, isolator and washer.
  10.  
  11. Remove the 2 rear HCU-to-mounting bracket bolts, isolators and washers.
  12.  
  13. Remove the HCU out through the exhaust tunnel in the floor pan of the vehicle.
  14.  

To install:
  1. Install the HCU into the vehicle correctly positioned on its mounting bracket.
  2.  
  3. Install the HCU-to-mounting bracket bolts, isolators and washers. Tighten the 3 mounting bolts to 248 inch lbs. (28 Nm).
  4.  
  5. Connect the 2 rear brake tubes to the proportioning valves and the right front brake tube to the HCU outlet port. Tighten the brake tube fittings to 159 inch lbs. (18 Nm).
  6.  
  7. Connect the 2 brake tubes coming from the master cylinder and the tube leading to the left front wheel to the HCU ports. Tighten the fittings to 159 inch lbs. (18 Nm).
  8.  
  9. Connect the brake tube routing clip to the HCU mounting bracket and tighten the attaching bolt.
  10.  
  11. Install the 6-way HCU wiring harness connector and the 10-way connector from the relay box to the HCU.
  12.  
  13. Install the HCU heat shield to the mounting bracket and tighten the attaching bolt.
  14.  
  15. Install the entire exhaust system.
  16.  
  17. Install the right inner fender splash shield.
  18.  
  19. Lower the vehicle.
  20.  
  21. Remove the brake pedal positioning tool from the vehicle.
  22.  
  23. Bleed the base brake system and the ABS hydraulic system.
  24.  
  25. Connect the negative battery cable.
  26.  
  27. Road test the vehicle to ensure proper operation of the base and ABS systems.
  28.  

1998 MODELS

See Figures 7 through 12

  1. Disconnect and isolate the negative battery cable.
  2.  
  3. Using a brake pedal positioning tool, or equivalent, depress the brake pedal past the first 1 inch of travel and hold in this position. This will isolate the master cylinder reservoir from the brake hydraulic system, which will prevent the brake fluid from draining out of the reservoir.
  4.  
  5. Raise and support the vehicle safely.
  6.  
  7. Remove the entire exhaust system.
  8.  
  9. Remove the right inner fender splash shield.
  10.  



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Fig. Fig. 7: Remove the HCU heat shield



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Fig. Fig. 8: Disconnect the chassis brake tubes from the HCU



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Fig. Fig. 9: Disconnect the primary and secondary brake tubes from the HCU

  1. Remove the HCU heat shield from the mounting bracket.
  2.  
  3. Using Brake Parts Cleaner, thoroughly clean all surfaces, brake line fittings and connections to the HCU.
  4.  
  5. Label and disconnect the 4 chassis brake tubes from the outlet ports of the HCU.
  6.  
  7. Disconnect the primary and secondary brake tubes coming from the master cylinder from the HCU inlet ports.
  8.  
  9. Remove the bolt attaching the front leg of the HCU mounting bracket to the front suspension crossmember.
  10.  



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Fig. Fig. 10: Remove the HCU mounting bracket's rear bolts



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Fig. Fig. 11: Unlock the CAB connector

  1. Remove the 2 bolts attaching the back legs of the HCU mounting bracket to the front suspension crossmember.
  2.  
  3. Remove the side HCU-to-mounting bracket bolt.
  4.  
  5. Remove the 2 bolts attaching the top of the HCU to the mounting bracket.
  6.  
  7. Disengage the 25-way wiring harness connector from the CAB by grasping the lock on the connector and pulling it out from the connector as far as it will go. This will remove the connector out from the CAB socket.
  8.  
  9. Remove the HCU from the vehicle by pulling it out through the area between the right halfshaft and frame rail.
  10.  

To install:
  1. Install the HCU into the vehicle correctly positioned on its mounting bracket.
  2.  
  3. Install the HCU-to-mounting bracket bolts, isolators and washers. Tighten the 3 mounting bolts to 97 inch lbs. (11 Nm).
  4.  
  5. Install the 25-way connector into the CAB socket. Install the connector in the following manner:
    1. Position the connector into the CAB socket and carefully push it down as far as it will go.
    2.  
    3. Once the connector is fully seated into the socket, push in the connector lock as far as it will go. This pulls the connector into the socket which locks it in the installed position.
    4.  

  6.  
  7. Install the 3 mounting bracket-to-suspension crossmember bolts and tighten to 250 inch lbs. (28 Nm).
  8.  



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Fig. Fig. 12: Use a torque wrench and crow's foot to properly tighten the brake tube fittings to the HCU

  1. Install the brake tubes to the HCU. Make sure that the correct brake tubes are installed in the correct openings. Using a crow foot and torque wrench, tighten the brake tube fittings to 145 inch lbs. (17 Nm).
  2.  
  3. Install the HCU heat shield to the mounting bracket and tighten the attaching bolt.
  4.  
  5. Install the entire exhaust system.
  6.  
  7. Install the right inner fender splash shield.
  8.  
  9. Lower the vehicle the vehicle.
  10.  
  11. Remove the brake pedal positioning tool from the vehicle.
  12.  
  13. Bleed the base brake system and the ABS hydraulic system.
  14.  
  15. Connect the negative battery cable.
  16.  
  17. Road test the vehicle to ensure proper operation of the base and ABS systems.
  18.  

Sebring Coupe and Avenger

See Figures 13 and 14

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Remove the left wheel.
  6.  
  7. Remove the left inner fender splash shield.
  8.  
  9. Remove the left headlight assembly.
  10.  
  11. Remove the air cleaner/inlet duct assembly.
  12.  
  13. Remove the Powertrain Control Module (PCM).
  14.  
  15. Remove the relay box bracket.
  16.  
  17. Using a flare nut wrench, disconnect and label the brake pipe connections.
  18.  



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Fig. Fig. 13: 1995-97 Hydraulic Control Unit assembly-1998 similar



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Fig. Fig. 14: On the 1998 HCU wiring harness, pull the pusher out to remove the connector

  1. Disengage the wiring harness connector from the Hydraulic Control Unit (HCU). On 1998 models, disengage the 25-way wiring harness connector by grasping the lock on the connector and pulling it out from the connector as far as it will go. This will remove the connector out from the socket.
  2.  
  3. Loosen the mounting bolts and remove the HCU/mounting bracket assembly from the vehicle.
  4.  
  5. Separate the HCU from the mounting bracket assembly.
  6.  

To install:
  1. Install the HCU to the mounting bracket and tighten the mounting bolts.
  2.  
  3. Install the HCU/mounting bracket assembly into the vehicle in proper position. Install and tighten the mounting bolts.
  4.  
  5. Plug in the wiring harness connector to the HCU. On 1998 models only, install the 25-way connector into the HCU socket. Install the connector in the following manner:
    1. Position the connector into the HCU socket and carefully push it down as far as it will go.
    2.  
    3. Once the connector is fully seated into the socket, push in the connector lock as far as it will go. This pulls the connector into the socket which locks it in the installed position.
    4.  

  6.  
  7. Install the brake pipe connections to the correct openings in the HCU. Tighten the brake pipe fittings to 11 ft. lbs. (15 Nm).
  8.  
  9. Install the relay box bracket.
  10.  
  11. Install the PCM.
  12.  
  13. Install the air cleaner/inlet duct assembly.
  14.  
  15. Install the left headlight assembly.
  16.  
  17. Install the left inner fender splash shield.
  18.  
  19. Install the left wheel. Tighten the lug nuts in a star pattern to 95 ft. lbs. (129 Nm).
  20.  
  21. Lower the vehicle.
  22.  
  23. Check the brake fluid level and add the proper amount.
  24.  
  25. Bleed the base brake system and the ABS hydraulic system.
  26.  
  27. Connect the negative battery cable.
  28.  

 
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