ABS Mark 60 (ABS, EDL, ASR and ESP), through 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.
- 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.
- Pull hydraulic unit with control module upward out of shock absorbers.
Control Module, Removing from Hydraulic Unit
• Separation from control module and hydraulic unit is not possible on vehicles with hydraulic brake booster or hill assist.
- Set hydraulic unit with control module downward onto a clean, level surface.
- Remove the inside E5 TORX(R) bolts - arrows - from the hydraulic pump.
The hydraulic pump must not be separated from the hydraulic unit.
Avoid build-up of static electricity!
- For this reason, secure hydraulic pump to hydraulic unit using red retainer - 1 - from replacement part set and two sealing plugs - 2 -.
- Carefully disconnect hydraulic unit with hydraulic pump upward at interface - 1 - from control module.
When removing 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 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.
• Before new control module can be assembled, pump motor adapter must first be inserted until it stops and engages. Adapter guide must not be damaged.
• The adapter supplied as replacement part for control module can be engage only once and then must not be separated again.
• The white grouting compound on base of control module serves as a seal and must not be removed.
• All contact surfaces on adapter, pressure sensor and control module as well as silicon gel and sealing elements must not be touched by hand or objects, soiled or damaged.
- Press adapter into adapter guide until it stops, it must then be engaged.
- Place control module without canting it onto hydraulic unit.
- Bolt hydraulic unit and control module with new TORX(R) 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.
• 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.
- 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.
