ABS/EDL/ASR/ESP Bosch 5.3, Assembly Overview, From Model Year 2000 - Vehicles From VIN 3B Y 000 001
ABS/EDL/ASR/ESP Bosch 5.3, assembly overview, from model year 2000 - Vehicles from VIN 3B Y 000 001
1 - Tandem brake booster
^ On gasoline engines the vacuum required is taken from the intake manifold.
^ As of model year 2001, vehicles with a gasoline engine and automatic transmission are equipped with a brake vacuum pump Brake system vacuum pump V192.
^ To produce vacuum with diesel engines, a vacuum pump is equipped.
^ Functional check:
- With engine switched off, depress brake pedal firmly several times (to exhaust the vacuum in the unit).
- Depress brake pedal with average foot pressure, hold and start engine. If the booster unit is working properly, the pedal will be felt to give slightly under foot (booster assist becomes effective).
- If faulty, replace completely.
2 - Brake line connection
^ To left rear brake caliper
^ Marked on hydraulic unit with "HL"
3 - Brake line connection
^ To right rear brake caliper
^ Marked on hydraulic unit with "HR"
4 - Brake line
^ Brake master cylinder/secondary piston circuit to hydraulic unit
^ Marked on hydraulic unit with "HZ2"
5 - Brake line
^ Hydraulic unit to hydraulic pump for traction control
^ Marked on hydraulic unit with "VLP"
^ Identification on the hydraulic pump for traction control "HE"
6 - Brake line
^ To left front brake caliper
^ Marked on hydraulic unit with "VL"
7 - Hex nut, 12 Nm
8 - Threaded stud
9 - Rubber bushing
10 - ABS hydraulic unit
11 - Brake line
^ To right front brake caliper
^ Marked on hydraulic unit with "VR"
12 - Bracket
13 - Hex head bolt, 9 Nm
14 - Rubber bushing
15 - Hydraulic pump for traction control
16 - Brake line
^ Brake master cylinder/primary piston circuit to hydraulic pump for traction control
^ Identification on the hydraulic pump for traction control "HZ"
17 - Hex nut, 9 Nm
18 - Rubber bushing
19 - Connection for traction control hydraulic pump
20 - Connection for brake fluid from brake fluid reservoir
^ Identification on the hydraulic pump for traction control "BA"
21 - Brake pressure sensor
^ Always replace together with the hydraulic pump for traction control.
22 - Bracket
^ Application Parts Catalog
23 - Rubber bushing
24 - Hex head bolt
25 - Tandem master cylinder
^ Cannot be repaired. If faulty, replace completely.
26 - T 45 torx socket head bolt, 25 Nm
27 - Self-locking nut, 49 Nm
28 - Sealing plug
^ Moisten with brake fluid and press into brake fluid reservoir
29 - Brake fluid reservoir
30 - Seal ring
31 - Cap
32 - Vacuum hose
^ Insert into brake booster unit
33 - Seal ring
Connection of brake lines from tandem master cylinder and the hydraulic pump for traction control to the hydraulic unit for ABS/EDL/ASR and ESP
A - Hydraulic unit to hydraulic pump for traction control
- Marked on hydraulic unit with "VLP",
- Identification on the hydraulic pump for traction control "HE"
B - Hydraulic unit to master cylinder secondary piston circuit
- Marked on hydraulic unit with "HZ2"
1 - Hydraulic unit to left front brake caliper
- Marked on hydraulic unit with "VL"
2 - Hydraulic unit to right front brake caliper
- Marked on hydraulic unit with "VR"
3 - Hydraulic unit to right rear brake caliper
- Marked on hydraulic unit with "HR"
4 - Hydraulic unit to left rear brake caliper
- Marked on hydraulic unit with "HL"
ABS Hydraulic Unit N55 with Hydraulic pump for traction control V156, removing and installing
Special tools, testers and auxiliary items required
^ Torque wrench V.A.G 1331
^ Brake pedal loading device V.A.G 1869/2
The ABS hydraulic unit N55 and hydraulic pump for traction control V156 are located in the left side of engine compartment.
1 - Hydraulic unit with ABS return flow pump
The hydraulic unit and ABS return flow pump form one unit and must always be replaced together if malfunction exists.
2 - Hydraulic pump for traction control with brake pressure sensor.
The hydraulic pump for traction control and the brake pressure sensor form one unit and must always be replaced together if malfunction exists.
CAUTION! Do not bend the brake lines in the area of the hydraulic unit!
Removing
- Note or request radio code on vehicles with coded radio if necessary.
- Disconnect battery.
- Release hydraulic unit connector - arrow 1 - and pull off - arrow 2 -.
- Install brake pedal loading device V.A.G 1869/2.
- Depress brake pedal with brake pedal loading device V.A.G 1869/2.
- Connect bleeder bottle hose to left front brake caliper bleeder screw and open bleeder screw.
- Close left front bleeder screw.
- Place sufficient lint-free cloths under hydraulic unit.
Make sure no brake fluid gets onto contacts.
These procedures are only for removing the hydraulic unit.
- Detach brake lines from the hydraulic unit.
- Plug brake lines and threaded holes with sealing plugs from repair kit Part No. 1H0 698 311 A.
- Remove hex nuts on bracket for hydraulic unit - arrows -.
- Remove hydraulic unit with control module.
These procedures are for removing the ABS hydraulic unit N55 and the hydraulic pump for traction control V156
- Remove power steering fluid reservoir - 1 - and set aside with hoses connected.
- Remove coolant reservoir - 2 - and set aside with coolant hoses connected.
Vehicles with electrical vacuum pump
- Remove electrical vacuum pump.
Continued for all vehicles
- Remove brake lines to the hydraulic unit and hydraulic pump for traction control.
- Plug brake lines and threaded holes with sealing plugs from repair kit Part No. 1H0 698 311 A.
- Disconnect connector from hydraulic pump for traction control.
- Pull off brake fluid supply hose from the hydraulic pump for traction control.
- Unfasten bolts on bracket for hydraulic unit.
- Remove the hydraulic unit with hydraulic pump for traction control upward.
Installing
^ Remove sealing plugs on new hydraulic unit when the corresponding brake line is going to be installed.
- Further installation is in the reverse sequence of removal.
To bleed the brake system, it is first necessary to activate the hydraulic pump for traction control V156.
- Perform the activation of the hydraulic pump for traction control in the base setting display group number 2 Perform base setting in "Guided Fault Finding" with Vehicle diagnostic, test and information system VAS 5051.
For this, use the Sprung button in the "Functions/Component selection".
- Bleed brake system Braking system, bleeding.
- Enter radio code.
- Perform control module coding Coding the control module with the Vehicle diagnostic, test and information system in. Guided Fault Finding
Tightening torques:
Nut for ABS hydraulic unit N55 to bracket.
Nut for Hydraulic pump for traction control V156 to bracket.
Bracket hex bolt to body.