ABS Mark 60 (ABS, EDL, ASR and ESP), Through 07.04.08

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 the toothed belt cover.

Diesel Engines with Particulate Filter

- Remove the exhaust pressure sensor 1, disconnect the electrical connectors, remove and lower the particulate filter.

Continuation for All

- Disengage the connector from the control module in - direction of arrow 1 - and disconnect in - direction of arrow 2 -.





- 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 and threaded holes immediately using sealing plugs from sealing plug repair kit (1H0 698 311 A).

- Mark the brake lines - 1 through 4 - for the brake calipers and remove and seal them.

- Pull the hydraulic unit with control module upward in - direction of arrow -.





Removing the 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 downward on to a clean, level surface.

- Remove the E5 Torx bolts - arrows - for 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 - from sealing plug repair kit (1H0 698 311 A).





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





When removing the control module, be sure that the hydraulic unit valve domes do not jam or get bent in the magnetic coils of the control module.





- 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 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.

• 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 engage 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 hands or objects, contaminated or damaged.

- Press the adapter into the 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

• 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 escape. If this occurs, unit may not be sufficiently filled or adequately bled.

- Installation is performed in the reverse order of removal.

- 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