ABS Control Module J104 (Bosch 5.7) Vehicles Without ESP, Removing and Installing

ABS Control Module J104 (Bosch 5.7) vehicles without ESP, removing and installing

Removing

CAUTION! Control module must only be removed from ABS hydraulic unit after hydraulic unit is removed from vehicle.

Note:
^ The following procedure outlines control module replacement only. A removed control module that has been in operation must always be replaced.
^ Thoroughly clean the hydraulic unit prior to removal from vehicle.
^ Prior to removing control module, check DTC memory.
^ Place hydraulic unit on a clean, level surface after removal.

- Remove ABS hydraulic unit.





- Release and disconnect electrical connection - 1 -.
- Remove screws - 1 -.





- Without twisting, separate control module - 2 - from hydraulic unit/valves.





- Thoroughly clean sealing surface - 2 - using plastic scraper - 1 -. Check valves - 3 - for damage.

Note:
^ Do not use aggressive cleaning materials or solvents. Where applicable, use cleaning materials supplied with replacement control module.
^ Check sealing surface for damage.

Installing

CAUTION! Ensure internal areas of the control module are free from contaminates and remains dry at all times.
Should the sealing surface or contacts be damaged, the hydraulic unit must be replaced.
Impacts of any kind (i.e.: by dropping or collision damage) can damage the hydraulic unit. Do not use a hydraulic unit that has experienced impact damage.





- Without twisting, carefully insert control module - 1 - onto hydraulic unit/valves - 2 - in direction of - arrow -.
- Edge of control module must slide over corresponding recess in hydraulic unit.

Note:
^ Always use new screws.
^ In order to ensure proper sealing of the gasket material, a new control module must not be removed and installed more than two times on the same hydraulic unit.
^ A removed control module that has been in operation must always be replaced.
^ In the event a new hydraulic unit is also installed, leave brake circuit protective caps in place until just prior to installing brake lines.
^ Should the brake circuit protective caps be removed prior to brake line installation, any brake fluid loss will adversely affect the system capacity and subsequent bleeding operation.





- Ensure control module is centered on hydraulic unit and then install new screws - 1 - and - 2 - evenly (do not tighten) so the gap between control module and hydraulic unit is equal on all sides.
- Install remaining screws - 3 - to - 6 - evenly (do not tighten).





- Torque screws - 1 - to - 6 - in numbered sequence to 2.5 Nm.





- Reconnect and secure electrical connection - 1 -.
- Reinstall hydraulic.
- Bleed brakes.
- Connect and use VAS 5051 / 5052 in operating mode "Guided Fault Finding" and perform On Board Diagnostic (OBD) program "Code ABS Control Module".