ABS Control Module -J104- /ABS Hydraulic Unit -N55-, REMOVING AND INSTALLING, LHD VEHICLES: Removing

Component Location Overview. Refer to Figure.

CAUTION:

Risk of destroying the brake lines by bending.

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

-- If the ABS Control Module -J104- must be replaced, use the Vehicle Diagnostic Tester.

-- Disconnect the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .

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

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

Hybrid vehicles

-- Remove the catalytic converter. Refer to CATALYTIC CONVERTER, REMOVING AND INSTALLING, FWD , CATALYTIC CONVERTER, REMOVING AND INSTALLING, AWD .

Vehicles with Diesel Engine:

-- Remove the Differential Pressure Sensor -G505- and the Exhaust Pressure Sensor 1 -G450- from the cylinder head cover. Refer to the appropriate Service Information .

-- If equipped, remove the Exhaust Pressure Sensor 1 -G450- from the cylinder head cover. Refer to EXHAUST GAS TEMPERATURE SENSOR, REMOVING AND INSTALLING, AWD , EXHAUST GAS TEMPERATURE SENSOR, REMOVING AND INSTALLING, FWD .

-- Remove the Exhaust Gas Temperature Sensor 3 -G495-. Refer to EXHAUST GAS TEMPERATURE SENSOR, REMOVING AND INSTALLING, AWD , EXHAUST GAS TEMPERATURE SENSOR, REMOVING AND INSTALLING, FWD .

-- Remove the Reducing Agent Injector -N474- from the emissions control module with the lines attached and move it to the right. Refer to the appropriate Service Information .

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

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-- If equipped, release and disconnect the connector -2- from the Heater Support Pump -V488-.

-- Remove the front exhaust pipe from the emissions control module. Refer to EXHAUST PIPES/MUFFLERS, DISCONNECTING .

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

Vehicles with diesel engine and AWD

-- Remove the driveshaft from the front bevel box. Refer to OVERVIEW - DRIVESHAFT and then move it to the side.

Vehicles with Biturbo Diesel Engine

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

-- Release and remove the connector -2- on the coolant expansion tank.

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

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

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

-- Place the coolant expansion tank -1- on the engine.

Continuation for all vehicles with diesel engine:

-- Position the Engine Support: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

CAUTION:

On AWD vehicles, insert the pendulum support as a spacer between the transmission and engine support with a longer bolt.

Use the front hole in the aluminum parts for this.

-- Push the engine with a hand slightly forward to position the second bolt.

-- Push the engine with the Engine Support:T10533 forward.

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Continuation for All Vehicles:

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

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

-- Release the connector -arrow B-.

-- Remove the connector -1-.

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

Fig 1: Identifying Brake Pedal Actuator

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

Fig 2: 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 3: Identifying V. A. G 1869/2

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-- 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 .

CAUTION:

Make sure no brake fluid gets on the contacts.

-- Remove the cover from the bulkhead and unclip the brake lines.

-- 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 kit part number 5Q0 698 311.

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

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

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

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-- Remove the hydraulic unit.