ABS Mark 70 (ABS/ASR)
ABS Mark 70 (ABS/ASR)
1. ABS control module J104
^ Removing and installing
2. ABS Hydraulic Unit N55
^ Removing and installing
3. Brake line
^ Master brake cylinder/primary piston circuit to hydraulic control unit
^ Identification: Tube fitting with threads M10 x 1
4. Brake line
^ Master brake cylinder/secondary piston circuit to hydraulic unit
^ Identification: Tube fitting with threads M12 x 1
5. Brake line
^ To left front brake caliper
^ Identification: Tube fitting with threads M12 x 1
6. Brake line
^ To right front brake caliper
^ Identification: Tube fitting with threads M10 x 1
7. Brake line
^ To left rear brake caliper
^ Identification: Tube fitting with threads M12 x 1
8. Brake line
^ To right rear brake caliper
^ Identification: Tube fitting with threads 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.
^ 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. Dual brake master cylinder
^ Cannot be serviced. Replace as complete unit if malfunctioning.
16. Hex nut, tighten to 25 Nm
^ Always replace after removal
17. Sealing plugs
^ Moisten with brake fluid and press into brake fluid reservoir
18. Brake fluid reservoir
19. Cap
20. Sealing plugs
^ Connection for vacuum hose
21. Vacuum hose
^ Insert into brake booster
22. Brake Booster Pressure Sensor G294
^ On vehicles with FSI engine without Hydraulic Brake Vacuum Boosting
Connection of brake lines from dual brake master cylinder to hydraulic unit
On tandem main brake cylinder:
A - Primary piston circuit of main brake cylinder to hydraulic unit
- Identification: Tube fitting with threads M10 x 1
B - Secondary piston circuit of main brake cylinder to hydraulic unit
- Identification: Tube fitting with threads 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 brake master cylinder
- Identification: Tube fitting with threads M10 x 1
B - Hydraulic unit to master cylinder secondary piston circuit
- Identification: Tube fitting with threads M12 x 1
1 - Hydraulic unit to left front brake caliper
- Identification: Tube fitting with threads M12 x 1
2 - Hydraulic unit to right front brake caliper
- Identification: Tube fitting with threads M10 x 1
3 - Hydraulic control unit to right rear brake caliper
- Identification: Tube fitting with threads M10 x 1
4 - Hydraulic control unit to left rear brake caliper
- Identification: Tube fitting with threads 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 the 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.
- Remove connecting pipe between intake hose and turbocharger.
- Remove upper part of toothed belt cover.
- Release control module connector in direction of - arrow 1 - and pull off - arrow 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
- Set hydraulic unit with control module upward on to a clean, level surface.
- Remove inner Torx bolts - arrows -.
- Pull control module off from hydraulic unit - arrow - without angling.
- Carefully pull off all sealing rings from valve domes of hydraulic unit.
CAUTION:
^ On a disconnected control module, circuit board is laid open.
^ No moisture or particles of dirt must penetrate in interior of control module.
^ The hydraulic pump must not be separated from the hydraulic unit.
- 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.
^ Surface must be cleaned before assembling.
- Slide all sealing rings - A - slightly over valve dome.
- Place control module without canting it on to hydraulic unit.
Sealing rings are then brought into their end position.
- Bolt hydraulic unit and control module with new inner 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.
^ When installing, make sure that rubber installation pieces are not pressed out of console.
- Installation is in the reverse order of removal.
- Remove Brake Pedal Actuator V.A.G 1869/2.
- Bleed braking system.
- Enter radio code.
- Code ABS Control Module J104 with in "Guided Fault Finding".
