Control Module And Hydraulic Unit, Removing And Installing, With Diesel Engine: Removing

Component Location:

The control module is bolted to the hydraulic unit and is located at right in the engine compartment.

CAUTION:

Risk of destroying the brake lines by bending.

Never forcefully bend the brake lines in the hydraulic unit area.

-- Remove the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

Vehicles with Emissions Control Module:

-- Remove the noise insulation. Refer to OVERVIEW - NOISE INSULATION .

-- Disconnect the connector -1-.

Fig 1: Identifying Clamping Sleeve

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-- Loosen the clamping sleeve -2- and slide it toward the rear.

-- Remove the bolts -1-.

Fig 2: Identifying Bolts

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-- Loosen the bolt -2- and remove the clamp.

-- Remove the front exhaust pipe.

NOTE:

Different heat shields -1- are installed depending on the engine.

-- Remove the bolts -arrows- and remove the heat shield -1- from the steering gear.

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-- Remove the bolts -1, 2 and 3- and remove the pendulum support.

Fig 3: Identifying Bolts

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Vehicles with Emissions Control Module and AWD:

-- Remove the front tunnel heat shield.

-- Remove the driveshaft from the front of the bevel box (refer to OVERVIEW - DRIVESHAFT ) and then move it to the side.

Continuation for Vehicles with Emissions Control Module:

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-- Position the : T10533 as shown and tighten the bolts hand-tight.

Bolt -3- = pendulum support original bolt
Install a M8 x 30 mm bolt -1- with a washer -2- in the threaded hole of the noise insulation.
-A- flat side
-B- high side

NOTE:

Additionally on AWD vehicles, insert a longer bolt in the front hole in the aluminum part of the pendulum support as a spacer between the transmission and engine support.

-- Push the engine with the : T10533 forward.

Continuation for All Vehicles:

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-- For vehicles with a heat shield, remove the heat shield -1-.

-- Unclip the wiring guide.

-- Press the locking mechanism downward in direction of -arrow A-.

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-- Release the connector in direction of -arrow B-.

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-- Remove the connector -1-.

-- Insert the : VAG1869/2 .

Fig 4: Identifying Brake Pedal Depressor V.A.G 1869/2

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-- Attach the bleeder bottle bleed hose -1- to the left front brake caliper breather valve.

Fig 5: Identifying Bleed Valve

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-- Open the breather valve.

-- Attach the bleeder bottle bleed hose -1- to the left rear brake caliper breather valve.

Fig 6: Identifying V.A.G 1869/2

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-- Open the breather valve.

-- Push the brake pedal at least 60 mm using the : VAG1869/2 .

-- Close the left front and left rear bleeder valves.

-- Do not remove the : VAG1869/2 .

-- Place enough lint-free cloths under the control module and hydraulic unit.

NOTE:

Make sure that no brake fluid gets into the contacts.

-- Remove the upper section of the heat shield mat from the bulkhead and fold it back.

-- Remove the brake lines from both brackets.

-- First, mark both brake lines from the brake master cylinder and remove from the hydraulic unit.

-- Immediately seal the threaded holes with the plugs from the assembly repair kit 5Q0 698 311.

-- Mark the remaining brake lines (brake calipers), remove them and seal off the threaded holes.

-- Place the dust caps for the bleeder valves on the brake lines.

-- Pull the hydraulic unit with the control module upward out of the shock absorbers in direction of -arrow-.

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-- Carefully place the hydraulic unit with the control module at the bottom of the engine compartment.

-- Raise the vehicle.

-- Remove the bracket in the vehicle from the hydraulic unit -arrows-.

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-- Guide out the hydraulic unit from the vehicle.