ABS Mark 70 (ABS/ASR)

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 the 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 the intake connection..

- Remove the intake flap motor.

2.0L Diesel Engine

- Remove connecting pipe between intake hose and turbocharger.

- Remove upper part of the toothed belt cover.

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 the (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

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

- Remove the Torx bolts - arrows -.





- Remove the control module from the hydraulic unit in - direction of arrow - without tilting.





- Carefully pull off all sealing rings from the valve domes of the hydraulic unit.

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.

• The hydraulic pump must not be separated from the hydraulic unit.

• 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.

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

• A new control module may be assembled on an already used hydraulic unit twice at maximum in order to guarantee the seal of the elastic gasket.

• 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.

• When installing, make sure that rubber installation pieces are not pressed out of the bracket.

- 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.

- Connect the battery..

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

Tightening Specifications