ABS Mark 60 (ABS, EDL, ASR and ESP), from Calendar Week 22.2008
Control Module and Hydraulic Unit, Removing
Special tools, testers and auxiliary items required
• Torque Wrench 5-50 Nm (V.A.G 1331)
• Torque Wrench (V.A.G 1410)
• Brake Pedal Actuator (V.A.G 1869/2)
Sealing Plug Repair Set, part no. 1H0 698 311 A
After separating the control module from the hydraulic unit, always install transport protection on the hydraulic unit for the valve domes.
Warranties will not be granted for hydraulic units without transport protection.
1 Transport protection for valve domes (foam)
2 Sealing Plug M 10
3 Sealing Plug M 12
Removing
Component location:
The control module is bolted to the hydraulic unit and is located at right in the engine compartment.
Do not bend the brake lines near the hydraulic unit.
- Read and note the present control module coding.
- Note or request radio code on vehicles with coded radio if necessary.
- Disconnect battery.
- Remove engine cover.
All Vehicles
- If equipped, remove the heat shield.
- Release control module connector in direction of arrow - 1 - and pull off - 2 -.
- Insert (V.A.G 1869/2).
- Attach bleeder hose of bleeder bottles to left-front and left-rear brake caliper bleeder valves and open bleeder valves.
- Operate brake pedal using (V.A.G 1869/2) at least 60 mm.
- Close left front and left rear bleeder valves.
- Do not remove (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 terminals.
- First, mark both brake lines from master cylinder - A and B - and remove 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 brake lines (brake caliper) - 1 to 4 -, unscrew and seal.
- Remove the hex bolt from the bracket.
- Remove the hydraulic unit, the control module and the retainer 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.
Control Module, Removing from Hydraulic Unit
•
- Set hydraulic unit with control module upward onto a clean, level surface.
- Remove the inner TORX(R) bolt from the control module.
- Pull control module off from hydraulic unit - arrow - without angling.
- Carefully pull off all sealing rings from valve domes of hydraulic unit.
• On a disconnected control module, circuit board is laid open.
• No moisture or particles of dirt must penetrate in interior of control module.
• Avoid build-up of static electricity!
- Cover control module magnetic coils with a lint free cloth.
After separating the control module and hydraulic unit, use transport protection for valve body.
New Control Module, Installing
Excessive shaking (for example dropping, impact) may destroy the control module. Control module must then no longer be used.
• Surface must be cleaned before assembling.
- Slide all sealing rings - A - slightly over the valve dome.
- Place control module without canting it onto hydraulic unit.
Sealing rings are then brought into their end position.
- Install the hydraulic unit and control module with the new inner TORX(R) 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.
• Do not install a used control module.
Control Module and Hydraulic Unit, Installing
• Do not remove sealing plugs at 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.
- Install in reverse order of removal.
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 (V.A.G 1869/2).
- Bleed brake system, refer to => [ Brake System, Bleeding ] Brake System, Bleeding
- Enter radio code.
- Code the ABS Control Module (J104) with the Vehicle diagnostic tester in "Guided Fault Finding".
A Steering Angle Sensor (G85) , Transverse Acceleration Sensor (G200) and Brake Pressure Sensor 1 (G201) basic setting must be done.
