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Diesel Engine

Fig 1: ICU Removal/Installation
GC0083968Courtesy of CHRYSLER GROUP, LLC
NOTE:

Before installation, be sure the mounting pins are installed in the ICU block, but do not install the mounting bracket.

  1. Install the ICU (1) into the engine compartment over the top of the engine cylinder head cover (2) as shown in illustration.
    Fig 2: Removing/Installing ICU Mounting Bracket
    GC0083967Courtesy of CHRYSLER GROUP, LLC
  2. Rotate the ICU (1) around behind the engine until the mounting bracket (2) can be installed.
  3. Install the mounting bracket (2) onto the ICU (1). Push the bracket mounting grommets onto the mounting pins of the ICU. Install the single mounting bolt (3). Tighten the mounting bolt to 11 N.m (97 in. lbs.).
    Fig 3: ICU Mounting
    GC0082347Courtesy of CHRYSLER GROUP, LLC
  4. Place mounting bracket for the ICU (1) over the mounting screws (2) and hang the assembly in place.
    Fig 4: Anti-Lock Brake Module Wiring Harness Connector
    GC0081322Courtesy of CHRYSLER GROUP, LLC
    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.

  5. Insert the ABM wiring harness connector (2) into the socket of the ABM (1) and close the cover, locking the connector in place.
    Fig 5: Identifying Brake Tubes At Hydraulic Control Unit
    GC0079880Courtesy of CHRYSLER GROUP, LLC
  6. Install the four chassis brake tubes (2, 3, 5, 6) brake tubes at the ICU hydraulic control unit (7). Tighten the tube nuts to 17 N.m (150 in. lbs.).
  7. Install the primary (4) and secondary (1) brake tubes at the ICU hydraulic control unit (7). Tighten the tube nuts to 17 N.m (150 in. lbs.).
  8. Push the brake tube bundle routing clips (with tubes) onto the studs on the dash panel.
  9. Install the heat shield on the dash panel and tighten the lower and upper mounting nuts.
  10. Install the air inlet tube at the air cleaner and engine cylinder head cover.
    Fig 6: ICU Mounting
    GC0082347Courtesy of CHRYSLER GROUP, LLC
  11. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
  12. Tighten the two mounting screws (2) attaching the ICU (1) mounting bracket to the body. Tighten the mounting screws to 23 N.m (17 ft. lbs.).
  13. Tighten the air inlet tube at the turbocharger.
  14. Lower the vehicle.
    Fig 7: Brake Pedal Holding Tool
    GC0098418Courtesy of CHRYSLER GROUP, LLC
  15. Remove brake pedal holding tool.
  16. Install the engine appearance cover.
  17. Connect the battery negative cable to the battery post. It is important that this be performed properly.
    Fig 8: Bleeding Brakes
    GC0079789Courtesy of CHRYSLER GROUP, LLC
  18. Hook up the scan tool to initialize the ABM and perform the following:
    1. Clear any faults.
    2. Fill the master cylinder to the proper fill level and bleed the base and ABS hydraulic systems. Refer to STANDARD PROCEDURE - BASE BRAKE BLEEDING and STANDARD PROCEDURE - ANTILOCK BRAKE SYSTEM BLEEDING  .
    3. Perform the ABS Verification Test and road test the vehicle. Refer to STANDARD PROCEDURE .
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