ABS/EDL/ASR/ESP Bosch 5.7, Assembly Overview, As of Model Year 2002
ABS/EDL/ASR/ESP Bosch 5.7, assembly overview, as of model year 2002
1 - Tandem brake booster
^ On gasoline engines the vacuum required is taken from the intake manifold.
^ Vehicles with a gasoline engine and automatic transmission are equipped with a vacuum pump for brakes 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.
^ With adhesive seal
2 - Brake line
^ Brake master cylinder/primary piston circuit to hydraulic unit
^ Marked on hydraulic unit with "HZ1"
3 - Brake line
^ Brake master cylinder/secondary piston circuit to hydraulic unit
^ Marked on hydraulic unit with "HZ2"
4 - Brake line
^ To left front brake caliper
^ Marked on hydraulic unit with "VL"
5 - Brake line
^ To right front brake caliper
^ Marked on hydraulic unit with "VR"
6 - Brake line
^ To right rear brake caliper
^ Marked on hydraulic unit with "HR"
7 - Brake line
^ To left rear brake caliper
^ Marked on hydraulic unit with "HL"
8 - Brake Pressure Sensor 1 G201
9 - ABS hydraulic unit
10 - ABS control module
11 - Locking clip
12 - Buffer
13 - Bracket
^ Application Parts Catalog
14 - Hex head bolt, 9 Nm
15 - Seal ring
16 - Tandem master cylinder
^ Cannot be repaired. If faulty, replace completely.
17 - Self-locking hex nut, 49 Nm
18 - T45 torx socket head bolt, 25 Nm
19 - Brake fluid reservoir
20 - Cap
21 - Sealing plug
^ Moisten with brake fluid and press into brake fluid reservoir
22 - Dowel bolt, 10 Nm
23 - Vacuum hose
^ Insert into brake booster unit
Connecting brake lines from tandem master cylinder to hydraulic unit
A - Hydraulic unit to master cylinder primary piston circuit
- Marked on hydraulic unit with "HZ1"
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 Control Module J104 and ABS Hydraulic Unit N55, 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
If the hydraulic unit is faulty the whole assembly must be replaced. If the control module is faulty it can be replaced separately from the hydraulic unit.
Location:
The control module is bolted to the hydraulic unit and is located in the engine compartment on the left side.
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.
Note: The hydraulic control unit - 1 - for the W8 is rotated 180 �.
- Remove coolant expansion tank - 2 - and set aside with coolant hoses connected.
- Release and remove connector from control module in the direction of - arrow -.
- Disconnect connector from brake pressure sensor.
- 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 lint-free cloths under the control module and hydraulic unit.
Make sure no brake fluid gets onto contacts.
- Disconnect brake lines from the hydraulic unit.
- Plug brake lines and threaded holes with sealing plugs from the repair kit Part No. 1H0 698 311 A.
- Release locking clips - 1 - from below and remove in direction of - arrow -.
- Remove hydraulic unit with control module.
Installing
Note:
^ Remove sealing plugs on new hydraulic unit when the corresponding brake line is going to be installed.
^ If the sealing plugs are removed too early, brake fluid can escape, and can no longer be guaranteed that the unit is sufficiently filled or adequately bled.
- Installation is in reverse order of removal.
- Bleeding 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:
Brake Pressure Sensor 1 G201, removing and installing
The Brake Pressure Sensor 1 G201 is located on the hydraulic control unit - 1 -.
Note: The hydraulic control unit - 1 - for the W8 is rotated 180°.
Removing
This work procedure does not apply to the W8:
- Unfasten coolant expansion tank - 2 - and set aside with coolant hoses connected.
This work procedure applies only to the W8:
- Unfasten power steering fluid reservoir - 3 - and set aside with hoses connected.
Continued for all vehicles
- Disconnect connector - 1 - from brake pressure sensor - 2 -.
- Place lint-free cloths under control module and hydraulic unit.
- Remove brake pressure sensor.
Installing
- Installation is in reverse order of removal.
Tightening torque:
- Bleed brake system Braking system, bleeding.