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

Control Module and Hydraulic Unit

Sealing Plug Repair Set, Part No. 1H0 698 311 A





1 Transport protection for valve domes (foam)
2 Sealing plug M 10
3 Sealing plug M 12

After separating the control module from the hydraulic unit, always install transport protection - 1 - on the hydraulic unit for the valve domes.

Warranties will not be granted for hydraulic units without transport protection.

Component Location

The control module is bolted to the hydraulic unit and is located on the right side in the engine compartment.

Removing

CAUTION!
Do not bend the brake lines near the hydraulic unit.

- Read and note the present control module coding.

- Note or request the radio code on vehicles with a coded radio, if necessary.

- Disconnect the battery.

- Remove the engine cover.

- Release the control module connector in - direction of arrow 1 - and pull off in - direction of arrow 2 -.





- Install the brake pedal actuator (VAG 1869/2).

- Attach the bleeder hose of the bleeder bottles to the left front and left rear brake caliper bleeder valves and open the bleeder valves.

- Press the brake pedal at least 60 mm using the brake pedal actuator (VAG 1869/2).

- Close the left front and left rear bleeder valves.

- Do not remove the brake pedal actuator (V.A.G 1869/2).

- Place sufficient lint free cloths under the control module and hydraulic unit.

Make sure that brake fluid does not come in contact with the electrical terminals.

- First, mark both brake lines - A and B - from the master cylinder and remove them from the hydraulic unit.





- Plug the brake lines and threaded holes immediately with sealing plugs from the repair kit part no. 1H0 698 311 A.

- Mark the brake lines - 1 to 4 - (from the brake caliper), and remove them from the hydraulic unit.

- Plug the brake lines and threaded holes immediately with sealing plugs from the repair kit part no. 1H0 698 311 A.

- Pull the hydraulic unit with control module upward off of the bracket.

Removing Control Module from Hydraulic Unit

• Separation of the control module and hydraulic unit is not possible on vehicles with a hydraulic brake booster or hill assist.

- Set the hydraulic unit with control module upward on to a clean, level surface.

- Remove the inner E5 Torx bolts - arrows - from the hydraulic pump.





CAUTION!
The hydraulic pump must not be separated from the hydraulic unit.

Avoid buildup of static electricity!

- For this reason, secure the hydraulic pump to the hydraulic unit using the red retainer - 1 - from the replacement part set and two sealing plugs - 2 -.





- Carefully remove the hydraulic unit with hydraulic pump upward at the interface - 1 - from the control module.





When removing the 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 the control module magnetic coils with a lint free cloth.

After separating the control module and hydraulic unit, use the transport protection for the valve body.

Installing New Control Module

CAUTION!
Excessive shaking (e.g. dropping, impact) may destroy the control module. Control module must then no longer be used.

• Before the new control module can be assembled, the pump motor adapter must first be inserted until it stops and engages. Adapter guide must not be damaged.

• The adapter supplied as a replacement part for the control module can be engaged only once and then must not be separated again.

• The white grouting compound on the base of the control module serves as a seal and must not be removed.

• All contact surfaces on the adapter, pressure sensor and control module as well as the silicon gel and sealing elements must not be touched by your hands or objects, contaminated or damaged.

- Press the adapter into adapter guide until it stops, it must then be engaged.

- Place the control module without tilting it onto the hydraulic unit.

- Bolt the hydraulic unit and control module together with the new Torx bolts supplied.

• 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.

Installing Control Module and Hydraulic Unit

• Do not remove the sealing plugs from the new hydraulic unit until the corresponding brake line is about to be installed.

• If the sealing plugs are removed too early, brake fluid can leak out. If this occurs, unit may not be sufficiently filled or adequately bled.

- Installation is performed in the reverse order of removal.

- Remove the brake pedal actuator (VAG 1869/2).

- Bleed the brake system. Refer to => [ Brake System Bleeding General Information ] Brake System Bleeding General Information.

- Enter radio code.

- Code the Anti-lock Brake System (ABS) control module using the in "Guided Fault Finding".

A steering angle sensor, transverse acceleration sensor and brake pressure sensor basic setting must be done.