ABS Mark 60 (ABS/EDL/ASR/ESP)
ABS Mark 60 (ABS/EDL/ASR/ESP)
1. ABS control module J104
Separation from control module and hydraulic unit is not possible on vehicles with hydraulic brake booster or hill assist.
2. ABS Hydraulic Unit N55
Separation from control module and hydraulic unit is not possible on vehicles with hydraulic brake booster or hill assist.
3. Brake line
^ Master brake cylinder/primary piston circuit to hydraulic control unit
^ Identification: Dia. 6.5 mm and tube fitting with longer thread M12 x 1
4. Brake line
^ Master brake cylinder/secondary piston circuit to hydraulic unit
^ Identification: Dia. 6.5 mm and tube fitting with longer thread M12 x 1
5. Brake line
^ To left front brake caliper
^ Identification: Dia. 5.25 mm and tube fitting with shorter thread M12 x 1
6. Brake line
^ To right front brake caliper
^ Identification: Dia. 5.25 mm and tube fitting with thread M10 x 1
7. Brake line
^ To left rear brake caliper
^ Identification: Dia. 5.25 mm and tube fitting with shorter thread M12 x 1
8. Brake line
^ To right rear brake caliper
^ Identification: Dia. 5.25 mm and tube fitting with thread M10 x 1
9. Inner Torx bolt, 5.5 Nm
^ Use new bolts.
10. Bracket
11. Hex bolt, 8 Nm
12. Gasket
^ For brake booster
13. Brake booster
^ On gasoline engines, vacuum is supplied from intake manifold.
^ Some vehicles with a gasoline engine and automatic transmission are equipped with a vacuum pump for brakes.
^ On vehicles with HBV, a vacuum sensor is installed
^ Functional check:
- With engine switched off, depress brake pedal firmly several times (to deplete vacuum in tool).
- Depress and hold brake pedal with average foot pressure and start engine. If brake booster is working properly, pedal will be felt to give noticeably under foot (booster assistance becomes effective).
^ Replace as a unit in the event of malfunction (previously, check all vacuum lines).
14. Sealing ring
15. Brake Booster Vacuum Sensor G483
^ Only on vehicles with HBV
16. Dual master brake cylinder
^ Cannot be serviced. Replace as complete unit if malfunctioning.
17. Heat shield
18. Hex nut, tighten to 25 Nm
^ Always replace after removal
19. Sealing plugs
^ Moisten with brake fluid and press into brake fluid reservoir
20. Brake fluid reservoir
21. Cap
22. Sealing plugs
^ Connection for vacuum hose
23. Vacuum hose
^ Insert into brake booster
Connection of brake lines from dual master brake cylinder to hydraulic unit
On tandem main brake cylinder:
A - Primary piston circuit of main brake cylinder to hydraulic unit
- Identification: Dia. 6.5 mm and tube fitting with thread M12 x 1
B - Secondary piston circuit of main brake cylinder to hydraulic unit
- Identification: Dia. 6.5 mm and tube fitting with thread M12 x 1
1 - Hydraulic unit to left front brake caliper
3 - Hydraulic control unit to right rear brake caliper
4 - Hydraulic control unit to left rear brake caliper
On hydraulic unit:
A - Hydraulic unit to primary piston circuit of master brake cylinder
- Identification: Dia. 6.5 mm and tube fitting with longer thread M12 x 1
B - Hydraulic unit to master cylinder secondary piston circuit
- Identification: Dia. 6.5 mm and tube fitting with longer thread M12 x 1
1 - Hydraulic unit to left front brake caliper
- Identification: Dia. 5.25 mm and tube fitting with shorter thread M12 x 1
2 - Hydraulic unit to right front brake caliper
- Identification: Dia. 5.25 mm and tube fitting with thread M10 x 1
3 - Hydraulic control unit to right rear brake caliper
- Identification: Dia. 5.25 mm and tube fitting with thread M10 x 1
4 - Hydraulic control unit to left rear brake caliper
- Identification: Dia. 5.25 mm and tube fitting with shorter thread M12 x 1
Control module and hydraulic unit, removing
Special tools, testers and auxiliary items required
^ Torque wrench V.A.G 1331
^ Torque wrench V.A.G 1410
^ Brake Pedal Actuator V.A.G 1869/2
Sealing plug repair set, part no. 1 H0 698 311 A
After separating control module from hydraulic unit, always install transport protection on hydraulic unit for valve domes.
Warranties will not be granted for hydraulic units without transport protection.
1 - Transport protection for valve domes (foam)
2 - Sealing plug M10
3 - Sealing plug M12
Removing
Component location:
The control module is bolted to the hydraulic unit and is located at right in engine compartment.
CAUTION: Do not bend brake lines near the hydraulic unit!
- Read out and note present control module coding.
- Note or request radio code on vehicles with coded radio if necessary.
- Disconnect battery.
- Remove engine cover.
- Release control module connector in direction of arrow - 1 - and pull off - 2 -.
- Install Brake Pedal Actuator V.A.G 1869/2.
- Attach bleeder hose of bleeder bottles to left-front and left-rear brake caliper bleeder valves and open bleeder valves.
- Operate brake pedal using Brake Pedal Actuator V.A.G 1869/2 at least 60 mm.
- Close left front and left rear bleeder valves.
- Do not remove Brake Pedal Actuator V.A.G 1869/2.
- Place sufficient lint-free cloths under control module and hydraulic unit.
Make sure that brake fluid does not come in contact with the terminals.
- First, mark both brake lines from master cylinder - A and B - and remove from hydraulic unit.
- Plug brake lines and threaded holes immediately with sealing plugs from repair kit Part No. 1H0 698 311 A.
- Mark brake lines (brake caliper) - 1 to 4 -, remove and seal.
- Pull hydraulic unit with control module upward out of shock absorbers.
Control module, removing from hydraulic unit
Note:
^ Separation from control module and hydraulic unit is not possible on vehicles with hydraulic brake booster or hill assist.
- Set hydraulic unit with control module downward on to a clean, level surface.
- Remove inner Torx bolts E5 - arrows - from hydraulic pump.
CAUTION: The hydraulic pump must not be separated from the hydraulic unit.
- For this reason, secure hydraulic pump to hydraulic unit using red retainer - 1 - from replacement part set and two sealing plugs - 2 -.
- Carefully disconnect hydraulic unit with hydraulic pump upward at interface - 1 - from control module.
When removing control module, be sure that the valve domes of the hydraulic unit do not jam or get bent in the magnetic coils of the control module.
Item - 2 - pump motor adapter.
- Cover control module magnetic coils with a lint free cloth.
After separating control module and hydraulic unit, use transport protection for valve body.
New control module, assembling
CAUTION: Excessive shaking (e.g. dropping, impact) may destroy the control module. Control module must then no longer be used.
^ Before new control module can be assembled, pump motor adapter must first be inserted until it stops and engages. Adapter guide must not be damaged.
^ The adapter supplied as replacement part for control module can be engage only once and then must not be separated again.
^ The white grouting compound on base of control module serves as a seal and must not be removed.
^ All contact surfaces on adapter, pressure sensor and control module as well as silicon gel and sealing elements must not be touched by hand or objects, soiled or damaged.
- Press adapter into adapter guide until it stops, it must then be engaged.
- Place control module without canting it on to hydraulic unit.
- Bolt hydraulic unit and control module with new Torx bolts supplied.
Note:
^ A new control module may be installed a max. of two times to a used hydraulic unit, to ensure that the elastic gasket seals sufficiently.
^ A control module which was once in driving operation must not be installed a second time.
Control module and hydraulic unit, installing
Note:
^ Do not remove sealing plugs at new hydraulic unit until the corresponding brake line is about to be installed.
^ If the sealing plugs are removed too early, brake fluid can escape. If this occurs, unit may not be sufficiently filled or adequately bled.
- Installation is in reverse order of removal.
- Remove Brake Pedal Actuator V.A.G 1869/2.
- Bleed braking system Bleeding braking system
- Enter radio code.
- Code ABS Control Module J104 with in "Guided Fault Finding".
A Steering Angle Sensor G85, Transverse Acceleration Sensor G200 and Brake Pressure Sensor 1 G201 basic setting must be done.
