Chrysler PT Cruiser Service & Repair Manual page 199

PT
ICU - INTEGRATED CONTROL UNIT (Continued)
CAUTION: The vacuum in the power brake booster
must be pumped down before removing the master
cylinder to prevent the booster from sucking in any
contamination. This can be done by pumping the
brake pedal while the engine is not running until a
firm brake pedal is achieved.
(1) With the engine not running, pump the brake
pedal 4-5 strokes until the pedal feel is firm.
(2) Unclip the air cleaner cover (two clips) and
move the cover aside.
(3) Remove the air cleaner housing by pulling
straight up.
(4) Disconnect the negative (ground) cable from
the battery and isolate the cable.
(5) Unlatch the power distribution center, lift it
up, and move it to the side.
(6) Remove the vehicle wiring harness connector
from brake fluid level switch in master cylinder
brake fluid reservoir (Fig. 21).
Fig. 21 Master Cylinder
1 - POWER BRAKE BOOSTER
2 - BRAKE FLUID LEVEL SWITCH
3 - MASTER CYLINDER
(7) Tag the brake tubes coming from the master
cylinder as primary and secondary (Fig. 22). This is
done to avoid mix-up once the tubes are removed
from the vehicle.
(8) Disconnect the two brake tubes from the mas-
ter cylinder primary and secondary ports (Fig. 22).
Install plugs at all of the open brake tube outlets on
the master cylinder.
(9) Disconnect and remove the primary and sec-
ondary brake tubes coming from the master cylinder
at the ICU hydraulic control unit (HCU) (Fig. 22).
(10) Clean the area around where the master cyl-
inder attaches to the power brake booster using a
suitable brake cleaner such as Mopar Brake Parts
Cleaner or equivalent.
Fig. 22 Primary and Secondary Brake Tubes
1 - PRIMARY BRAKE TUBE
2 - SECONDARY BRAKE TUBE
3 - BRAKE TUBES FROM MASTER CYLINDER
(11) Remove the two nuts attaching the master
cylinder to the power brake booster.
(12) Slide the master cylinder straight out of the
power brake booster.
(13) Disconnect the brake tubes going to each indi-
vidual brake at the HCU (Fig. 23).
Fig. 23 ICU Connections
1 - ICU MOUNTING BOLTS
2 - CAB CONNECTOR
3 - BRAKE TUBES TO BRAKES
(14) Disconnect the 24-way connector from the con-
troller antilock brake (CAB) mounted on the inte-
grated control unit (ICU) and move it out of the way
(Fig. 23). The connector is disconnected by pulling
outward on the connector lock. This will unlock and
raise the 24-way connector out of the socket on the
CAB.
(15) Remove the 3 bolts attaching the ICU to its
mounting bracket (Fig. 23).
BRAKES - ABS 5 - 91