Control Module And Hydraulic Unit, Removing And Installing, LHD, Bi-Turbo Diesel Engine: Removing

Component Location:

The control module is bolted to the hydraulic unit -1- and is located in the engine compartment on the right side.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

CAUTION:

Risk of destroying the brake lines by bending.

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

-- Read and note the present control module code.

-- On vehicles with a coded radio, note the code. Retrieve it if necessary.

-- Disconnect the battery. Refer to OVERVIEW - NOISE INSULATION .

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

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

-- Release and remove the connector -1- for the Oil Level Thermal Sensor -G266-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Release and remove the connector -2- from the Heater Support Pump -V488-.

-- To do so, open the catch -3- in the -direction of the arrow- and release the connector.

-- Remove the front exhaust pipe. Refer to EXHAUST TEMPERATURE REGULATION COMPONENTS, REMOVING AND INSTALLING .

-- Remove the pendulum support. Refer to PENDULUM SUPPORT, REMOVING AND INSTALLING .

-- Remove the driveshaft on the front bevel box and then move it to the side. Refer to OVERVIEW - DRIVESHAFT / DRIVESHAFT, REMOVING AND INSTALLING .

-- Position the Engine Support:T10533 -A- as shown.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Position the Engine Support:T10533/2 -B- on the flat threaded connection point of the Engine Support:T10533/1 .

-- Install the original bolt of the pendulum support -1- in the front threaded hole of the pendulum support.

-- Install a M8 x 60 mm bolt -2- with a washer in the left threaded hole of the noise insulation.

-- Establish a distance of 20 mm -a- between the threaded connection height and the subframe using washers.

-- Tighten the bolts hand-tight.

-- Push the engine with the Engine Support:T10533 as far forward as possible.

-- Unclip the reducing agent delivery line -2- on the coolant expansion tank and on the toothed belt guard -B arrows-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Open the couplings -A- and -B- and remove the fuel lines. Disconnect the couplings. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

Fig 1: Identifying Fuel Line Couplers

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

CAUTION:

The fuel system is under pressure.

Risk of injury from fuel spraying out.

- Wear protective eyewear.

- Wear safety gloves.

- Reduce the pressure: place clean cloths around the connection point and carefully open the connection point.

-- Unlock and disconnect the connector -2- on the coolant reservoir.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Unclip, disconnect and remove the connector -4-.

-- Unclip the bracket for the fuel lines from the coolant expansion tank -arrow-.

-- Release the catches with a screwdriver -6-.

-- Lay the coolant reservoir -1- on the engine.

-- Remove the fuel filter and place it with the fuel hoses connected on the engine. Refer to FUEL FILTER .

-- Remove the Exhaust Gas Temperature Sensor 3 -G495-. Refer to EXHAUST TEMPERATURE REGULATION COMPONENTS, REMOVING AND INSTALLING or appropriate service information .

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Unclip the wiring guide.

-- Press the locking mechanism downward -arrow A-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Release the connector -arrow B-.

-- Remove the connector -1-.

-- Insert the Brake Pedal Actuator:VAG1869/2 .

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Fig 3: Identifying Bleed Valve

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Open the breather valve.

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

Fig 4: Identifying V.A.G 1869/2

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Open the breather valve.

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

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

-- Do not remove the Brake Pedal Actuator:VAG1869/2 .

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

NOTE:

Make sure no brake fluid gets on the contacts.

-- First mark both brake lines of the brake master cylinder -5- and -6- and remove them from the hydraulic unit.

Fig 5: Brake Lines, Attaching To Hydraulic Unit Sequence

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove both brake lines -5- and -6- from the brake master cylinder. Refer to BRAKE MASTER CYLINDER, REMOVING AND INSTALLING, LHD BI-TURBO DIESEL ENGINE .

-- Unclip the brake lines from the brake lines as far as possible.

-- 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.

-- Remove the right front brake line -3-.

-- 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 -arrow-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Guide out the hydraulic unit downward out of the vehicle.