ABS Mark 60 (ABS, EDL, ASR and ESP), From 07.06.08
Control Module and Hydraulic Unit
Special tools, testers and auxiliary items required
• Torque wrench 5-50 Nm (VAG 1331)
• Torque wrench (VAG 1410)
• Brake pedal actuator (VAG 1869/2)
Sealing Plug Repair Kit (1H0 698 311 A)
1 Transport protection for valve domes (foam)
2 M10 sealing plugs
3 M12 sealing plugs
After separating the control module from the hydraulic unit, always install the transport protection - 1 - to the hydraulic unit valve domes.
Warranties will not be granted for hydraulic units without transport protection.
Removing
Component location:
The control module is bolted to the hydraulic unit and is located on the right side in the engine compartment.
CAUTION!
Do not bend the brake lines near the hydraulic unit.
- Read and note the present control module coding.
- Disconnect the battery..
- Remove the engine cover.
1.9L Diesel Engine
- Disconnect the connection hose to intake connection.
- Remove the intake flap motor.
2.0L Diesel Engine
- Remove the connecting pipe between the intake hose and turbocharger.
- Remove the upper part of toothed belt cover.
Diesel Engines with Particulate Filter
- Disconnect the connector for the Exhaust Gas Temperature (EGT) sensor 4 - 2 - and the Heated Oxygen Sensor (HO2S) - 3 -.
- Unclip the EGT sensor 4 and the HO2S wires from the brackets on the plenum chamber and engine.
- Disconnect the electrical connector - 1 - for the exhaust pressure sensor 1.
- Remove the bolt - 2 - and then remove the bracket - 3 - together with the exhaust pressure sensor 1 in - direction of arrow -.
- Move the bracket - 3 - and the exhaust pressure sensor 1 forward.
- Remove the engine cover
- Remove the particulate filter bracket bolt - 1 -.
- Raise the vehicle.
- Loosen and remove the turbocharger/particulate filter clamp - 1 -.
• The illustration shows the clamp - 1 - bolt from underneath. In some cases, this can be removed from the top.
- Remove the exhaust system bracket bolts - arrows - and bracket from the subframe.
- Remove the bolts - 1 - and remove the drive axle heat shield - 2 -.
- Disconnect the right drive axle from the flange, lay it down and secure it.
- Loosen the double clamp on the exhaust pipe and push it toward the rear.
- Remove the nuts - 1 - and lower the particulate filter.
- Remove the nuts - 2 - and remove the particulate filter bracket - 3 -.
- Lower the particulate filter just enough so that it touches the steering gear.
• While lowering the particulate filter, pay close attention to the cable, the EGT sensor 4 and the (HO2S to prevent damage.
- Lower the vehicle.
Continuation for All
- Remove the bolts - 1 - and remove the heat shield - 2 -, if equipped.
- Release and disconnect the connector from the control module in - direction of arrow -.
- Install the (VAG 1869/2).
- Attach the bleeder hose from the bleeder bottles to the left front and left rear brake caliper bleeder valves and open the bleeder valves.
- Operate the brake pedal using (VAG 1869/2) at least 60 mm.
- Close the left front and left rear bleeder valves.
- Do not remove the (VAG 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 terminals.
- First mark both brake lines for the master cylinder - A - and - B - and remove them from the hydraulic unit.
- Seal the brake lines - A and B - and threaded holes using sealing plugs from the sealing plug repair kit (1H0 698 311 A).
- Mark the brake lines - 1 through 4 - for the brake calipers and remove them.
- Seal the brake lines - 1 through 4 - and threaded holes using sealing plugs from the sealing plug repair kit (1H0 698 311 A).
- Remove the bolt form the bracket - arrow -.
- Remove the hydraulic unit, with control module and the side retainer in - direction of arrow - from the bracket rubber insulation and turn it on its head.
- Remove the retainer from the hydraulic unit in the engine compartment.
- Remove the hydraulic unit and the control module.
Removing the Control Module from Hydraulic Unit
•
- Set the hydraulic unit with control module upward on to a clean, level surface.
- Remove the Torx bolts from the control module.
- Pull control module off from hydraulic unit - arrow - without tilting.
- Carefully pull off all sealing rings from the hydraulic unit valve domes.
CAUTION!
• On a disconnected control module, the circuit board is exposed.
• No moisture or particles of dirt must penetrate in the interior of the control module.
• Avoid buildup of static electricity!
- 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 the New Control Module
CAUTION!
Excessive shaking (e.g. dropping, impact) may destroy the control module. The control module must then no longer be used.
• Surface must be cleaned before assembling.
- Slide all sealing rings - A - slightly over the valve domes.
- Place the control module, without tilting it onto the hydraulic unit.
The sealing rings are then brought into their end position.
- Install the hydraulic unit and control module with the new Torx bolts diagonally according to the tightening specification.
• 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
• Do not remove the sealing plugs from a 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 performed in the reverse order of removal.
CAUTION!
When installing the mount, make sure the rubber insulation does not push out of the bracket. After installing, make sure the hydraulic unit and the control module are secure, otherwise malfunctions will register.
- Remove the (VAG 1869/2).
- Bleed the brake system. Refer to --> [ Brake System, Bleeding ] Brake System, Bleeding
- Code the Anti-lock Brake System (ABS) control module using "Guided Fault Finding".
When doing this, a basic setting of the steering angle sensor, transverse acceleration sensor and brake pressure sensor must be performed.
Tightening Specifications
