ABS Mark 60, ABS, EDL, ASR and ESP, Through 05.08

Hydraulic Unit and Brake Booster/Master Cylinder Assembly Overview





1 Anti-lock Brake System (ABS) control module (w/Electronic Differential Lock (EDL) (J104)

Separation from control module and hydraulic unit is not possible on vehicles with hydraulic brake booster or hill assist.

• Removing and installing, refer to => [ Brake Lines, Connecting to Master Cylinder and Hydraulic Unit ] Brake Lines, Connecting to Master Cylinder and Hydraulic Unit.

2 ABS hydraulic unit (N55)

Separation from control module and hydraulic unit is not possible on vehicles with hydraulic brake booster or hill assist.

• Removing and installing, refer to => [ Brake Lines, Connecting to Master Cylinder and Hydraulic Unit ] Brake Lines, Connecting to Master Cylinder and Hydraulic Unit.

3 Brake line

• Master cylinder/primary piston circuit to hydraulic control unit.

• Identification: 6.5 mm diameter and tube fitting with longer M12 x 1 threads.

4 Brake line

• Master cylinder/secondary piston circuit to hydraulic unit.

• Identification: 6.5 mm diameter and tube fitting with longer M12 x 1 threads.

5 Brake line

• To left front brake caliper.

• Identification: 5.25 mm diameter and tube fitting with shorter M12 x 1 threads.

6 Brake line

• To right front brake caliper.

• Identification: 5.25 mm diameter and tube fitting with M10 x 1 threads.

7 Brake line

• To left rear brake caliper.

• Identification: 5.25 mm diameter and tube fitting with shorter M12 x 1 threads.

8 Brake line

• To right rear brake caliper.

• Identification: 5.25 mm diameter and tube fitting with M10 x 1 thread.

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

• Vacuum is supplied from the intake manifold.

• Some vehicles with a automatic transmission are equipped with a vacuum pump for the brakes. Refer to => [ Brake System Vacuum Pump ] Brake System Vacuum Pump.

• On vehicles with a hydraulic brake booster, a vacuum sensor is installed. Refer to => [ Brake Booster Vacuum Sensor ] Brake Booster Vacuum Sensor.

• Function test:

- With engine switched off, press brake pedal firmly several times (to deplete vacuum).

- Press 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).

• Removing and installing, refer to => [ Brake Booster ] Brake Booster.

14 Seal

15 Brake booster vacuum sensor (G483)

• Only on vehicles with a hydraulic brake booster.

• Removing and installing, refer to => [ Brake Booster Vacuum Sensor ] Brake Booster Vacuum Sensor.

16 Master cylinder

• Cannot be serviced. Replace as complete unit if malfunctioning.

• Removing and installing, refer to => [ Master Cylinder ] Service and Repair.

17 Heat shield

18 Hex nut, 25 Nm

• Always replace after removal.

19 Sealing plugs

• Lubricate 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.