INSTALLATION
- INTEGRATED CONTROL UNIT - GAS ENGINE
- INTEGRATED CONTROL UNIT - DIESEL ENGINE
- INTEGRATED CONTROL UNIT - RIGHT-HAND-DRIVE
INTEGRATED CONTROL UNIT - GAS ENGINE
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. Place the mounting bracket for the ICU (1) over the mounting screws (2) and hang the assembly in place. Tighten the two mounting screws (2) to 23 N·m (17 ft. lbs.).
CAUTION: Before installing the ABM harness connector on the ABM, be sure the seal is properly installed in the connector.
3. Insert the ABM wiring harness connector (2) into the socket of the ABM (1) and close the cover, locking the connector in place.
4. 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.).
5. 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.).
6. Position the power steering pressure hose routing clamp (2) on the exhaust manifold and install the mounting screw (1). Tighten the mounting screw to 9 N·m (80 in. lbs.).
7. Push the brake tube bundle routing clips (with tubes) onto the studs on the dash panel.
8. Install the heat shield on the dash panel and tighten the lower and upper mounting nuts.
9. Remove the brake pedal holding tool.
10. Install the engine appearance cover.
11. Connect the battery negative cable to the battery post. It is important that this be performed properly. (Refer to 8 - ELECTRICAL/BATTERY SYSTEM - STANDARD PROCEDURE)
12. Hook up the scan tool to initialize the ABM and perform the following:
a. Clear any faults.
b. Fill the master cylinder to the proper fill level and bleed the base and ABS hydraulic systems. (Refer to 5 - BRAKES - ABS - STANDARD PROCEDURE)
c. Check for leaks.
d. Perform the ABS Verification Test and road test the vehicle.
INTEGRATED CONTROL UNIT - DIESEL ENGINE
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.
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.).
4. Place mounting bracket for the ICU (1) over the mounting screws (2) and hang the assembly in place.
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.
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.
11. Raise and support the vehicle. (Refer to LUBRICATION & MAINTENANCE/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.
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. (Refer to 8 - ELECTRICAL/BATTERY SYSTEM - STANDARD PROCEDURE)
18. Hook up the scan tool to initialize the ABM and perform the following:
a. Clear any faults.
b. Fill the master cylinder to the proper fill level and bleed the base and ABS hydraulic systems. (Refer to 5 - BRAKES - ABS - STANDARD PROCEDURE)
c. Perform the ABS Verification Test and road test the vehicle.
INTEGRATED CONTROL UNIT - RIGHT-HAND-DRIVE
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. Install the ICU with bracket (1) into the engine compartment. Place the mounting bracket for the ICU (1) over the mounting stud and screw (3) and hang the assembly in place. Tighten the mounting nut (2) and mounting screw (3) to 23 N·m (17 ft. lbs.).
CAUTION: Before installing the ABM harness connector on the ABM, be sure the seal is properly installed in the connector.
3. Insert the ABM wiring harness connector (2) into the socket of the ABM (1) and close the cover, locking the connector in place.
4. 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.).
5. 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.).
6. Install the air cleaner housing (1). (Refer to 9 - ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - INSTALLATION)
7. Remove the brake pedal holding tool.
8. Install the engine appearance cover.
9. Connect the battery negative cable to the battery post. It is important that this be performed properly. (Refer to 8 - ELECTRICAL/BATTERY SYSTEM - STANDARD PROCEDURE)
10. Hook up the scan tool to initialize the ABM and perform the following:
a. Clear any faults.
b. Fill the master cylinder to the proper fill level and bleed the base and ABS hydraulic systems. (Refer to 5 - BRAKES - ABS - STANDARD PROCEDURE)
c. Check for leaks.
d. Perform the ABS Verification Test and road test the vehicle.