Chrysler PT Cruiser Service & Repair Manual page 201

PT
ICU - INTEGRATED CONTROL UNIT (Continued)
(4) Install the four brake tubes going to the brakes
into their respective outlet ports on the ICU HCU
(Fig. 23). Using a crow foot on a torque wrench,
tighten the four brake tube nuts to a torque of 17
N·m (145 in. lbs.).
(5) Wipe the face of the power brake booster clean
where the master cylinder seal comes in contact
when it's installed. Do not get any cleaner or debris
inside the booster.
(6) Position the master cylinder on the studs of the
power brake booster, aligning the push rod of the
power brake booster with master cylinder piston
push rod. Carefully push the master cylinder onto
the studs until it contacts the face of the booster.
(7) Install the two master cylinder mounting nuts
and tighten each to a torque of 18 N·m (160 in. lbs.).
NOTE: When installing the brake tubes from the
master cylinder on the HCU, the brake tube with the
small tube nut is to be installed in the forward-most
port on the HCU with the small end going toward
the master cylinder secondary port.
(8) Install the primary and secondary brake tubes
from the master cylinder onto the HCU (Fig. 22). Do
not completely tighten the primary and secondary
tubes at this time.
(9) Connect the two brake tubes to the master cyl-
inder primary and secondary ports (Fig. 22).
(10) Using a crow foot on a torque wrench, tighten
the primary and secondary brake tube nuts at both
the master cylinder and HCU to a torque of 17 N·m
(145 in. lbs.).
(11) Connect the brake fluid level switch wiring
connector.
(12) Install the power distribution center.
(13) Connect the negative (ground) cable on the
battery.
(14) Install the air cleaner housing.
(15) Install the air cleaner cover.
(16) Hook up the DRBIII
CAB.
(17) Fill the master cylinder to the proper fill level
and bleed the base and ABS hydraulic systems.
(Refer to 5 - BRAKES - ABS - STANDARD PROCE-
DURE)
(18) Road test the vehicle to ensure proper opera-
tion of the base and antilock brake systems.
BRAKES - ABS 5 - 93
to initialize the new