Control Module And Hydraulic Unit, Abs Mark 20 IE, Through 09.00
Special tools and workshop equipment required
- Torque wrench V.A.G 1331
- Torque wrench V.A.G 1410
- Brake pedal actuator V.A.G 1869/2
Removing
Location: The control module is bolted to the hydraulic unit and is located at left in the engine compartment.
Do not bend brake lines near the hydraulic unit!
-- Note radio code (for vehicles equipped with coded anti-theft radio).
-- Disconnect battery.
-- Disconnect intake air duct -1- and connector -2- from Mass Air Flow (MAF) sensor -G70-.
-- Remove bolts -3-, -4- and -5-.
-- Remove complete air filter.
With 2.0 L and 1.8 L Engines
-- Remove protective housing for relay from cable channel.
Continuation for All
-- Extract as much brake fluid as possible from brake fluid reservoir using a bleeder bottle.
-- Insert brake pedal actuator V.A.G 1869/2.
-- Operate brake pedal using brake pedal actuator V.A.G 1869/2.
-- Attach bleeder bottle bleeder hose to left-front brake caliper bleeder screw and open bleeder screw.
-- Close left front bleeder screw.
-- Disconnect connector of ABS control module -J104 - -arrow 1- and disconnect -arrow 2-.
-- Place a sufficient number of lint-free cloths under control module and hydraulic unit.
Make sure that brake fluid does not come in contact with the terminals.
-- Remove brake lines from ABS hydraulic unit -arrows- to brake master cylinder and tie up.
-- Remove remaining brake lines from ABS hydraulic unit -N55-.
-- Seal brake lines and threaded bores using plugs from repair kit 1H0 698 311 A.
-- Remove bolts on bracket for ABS hydraulic unit -N55- -arrows-.
-- Remove ABS hydraulic unit -N55- together with ABS control module -J104-.
ABS Control Module, Removing from Hydraulic Unit
-- Remove outer Torx bolts E 5 -arrows- from ABS control module -J104- and remove ABS control module --.
When removing ABS control module -J104-, be sure that the valve domes of the hydraulic unit do not jam or get bent in the magnetic coils of the control module.
Cover magnetic coils of ABS control module -- with a lint free cloth.
After disconnecting ABS control module -J104- and ABS hydraulic unit -N55-, use transport protection for valve domes.
Installing
Do not remove sealing plugs at new hydraulic unit until the corresponding brake line is about to be installed.
If the sealing plugs are removed too early, brake fluid can escape. If this occurs, unit may not be sufficiently filled or adequately bled.
When attaching control module and hydraulic unit, be sure that the valve domes of the hydraulic unit do not jam or get bent in the magnetic coils of the control module.
-- Bolt control module to the hydraulic unit using new bolts. Note tightening specification: max. 4 Nm.
-- Bolt ABS unit to bracket.
Do not tighten bolts completely. It will be easier to attach the various brake lines to the hydraulic unit.
-- Tighten hydraulic unit after tightening brake lines.
-- Rest of installation is in reverse order of removal.
-- Bleed brake system BRAKE SYSTEM BLEEDING GENERAL INFORMATION .
-- Code radio.
-- Code control module.
| Tightening Specifications | |
|---|---|
| Control module to hydraulic unit | max. 4 Nm |
| Hex-bolt for hydraulic unit to bracket | 8 Nm |
| Nut for tandem master brake cylinder to brake booster | 20 Nm |
| Brake lines to ABS control module: | |
| M10 x 1 thread | 14 Nm |
| M12 x 1 thread | 14 Nm |
| Hex nut to body | 20 Nm |
| Cap nut to body | 20 Nm |