ABS Bosch 5.3 From Model Year 2000 - Vehicles From VIN 3B Y 000 001
ABS Bosch 5.3 from model year 2000 - Vehicles from VIN 3B Y 000 001
With the following versions: ABS; ABS/EDL and ABS/EDL/ASR
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
5 - Brake line
^ Brake master cylinder/primary piston circuit to hydraulic unit
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 - Control module and 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 - Bracket
^ Application Parts Catalog
15 - Rubber bushing
16 - Hex head bolt
17 - Tandem master cylinder
^ Cannot be repaired. If faulty, replace.
18 - T45 torx socket head bolt, 25 Nm
19 - Self-locking nut, 49 Nm
20 - Sealing plug
^ Moisten with brake fluid and press into brake fluid reservoir
21 - Brake fluid reservoir
22 - Sealing ring
23 - Cap
24 - Vacuum hose
^ Insert into brake booster unit
25 - Seal ring
Connecting tandem master cylinder brake lines to hydraulic unit for ABS/EDL front and all wheel drive (AWD), as well as ABS/EDL/ASR front wheel drive (FWD)
A - Secondary piston circuit
B - Primary piston circuit
1 - Hydraulic unit to left rear brake caliper
2 - Hydraulic unit to right rear brake caliper
3 - Hydraulic unit to right front brake caliper
4 - Hydraulic unit to left front brake caliper
ABS Control Module, removing and installing separately
Special tools, testers and auxiliary items required
^ Torque wrench V.A.G 1783
- For vehicles equipped with coded anti-theft radio, note radio code, obtain if necessary.
- Disconnect battery.
- Remove left front wheel.
- Remove left front wheel housing liner.
- Loosen power steering fluid reservoir.
- Remove tank for windshield washer system.
- Thoroughly clean control module, hydraulic unit and surrounding area.
- Vacuum clean control module, hydraulic unit and surrounding area in order to prevent dirt and moisture from entering the unit.
- Disengage connector - arrow 1 - and disconnect - arrow 2 - from control module.
- Disengage and disconnect harness connector - 1 -.
- Remove bolts - 1 - and pull control module - 2 - off hydraulic unit without canting.
- Clean sealing surface - 2 - using plastic scraper - 1 - enclosed.
- Check valves - 3 - for damage.
Note:
^ Do not use aggressive cleaning agents (use cleaning agent enclosed).
^ Check sealing surface for damage (visual check).
CAUTION! No moisture or particles of dirt must penetrate in interior of control module.
If sealing surface or contact tags are damaged, hydraulic unit must be replaced.
Excessive shaking (e.g. dropping, impact) may destroy the control module. Control module must then no longer be used.
- Carefully slide control module - 1 - onto hydraulic unit - 2 -. Make sure valves do not cant.
- Control module housing edge must glide over offset on hydraulic unit.
Note:
^ Use new bolts.
^ A new control module may be assembled on an already used hydraulic unit a maximum of two times in order to guarantee the seal of the elastic gaskets.
^ A control module which was once in driving operation must not be installed a second time.
- Press control module onto hydraulic unit and install new bolts - 1 and 2 - evenly (do not tighten) until control module makes contact evenly on hydraulic unit.
- Install bolts - 1 to 6 - until making contact, do not tighten.
- Now tighten bolts in the specified sequence to tightening torque of 2.5 Nm.
- Install harness connector - 1 -.
- Code radio.
- If control module is codeable, code control module Coding control module using Vehicle Diagnosis, Testing and Information System VAS 5051, via "Guided Fault Finding".
Tightening torque:
Control module and hydraulic unit, 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.
- Release control module connector - arrow 1 - and pull off - arrow 2 -.
- Connect bleeder bottle hose to left front brake caliper bleeder screw and open bleeder screw.
- Install brake pedal loading device V.A.G 1869/2.
- Depress brake pedal with brake pedal loading device V.A.G 1869/2.
- Close left front bleeder screw.
- Place sufficient lint-free cloths under the control module and hydraulic unit.
- Detach 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.
- Unfasten nuts on hydraulic unit bracket - arrows -.
- 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 filled or adequately bled.
- Further Installation is in reverse order of removal.
- Bleed brake system.
- 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:
Hydraulic unit nut to bracket