ABS TRW (ABS/EDS/ASR/Esp)
ABS TRW (ABS/EDS/ASR/ESP)
1. ABS control module J104
It is not possible to separate control module and hydraulic unit.
2. ABS Hydraulic Unit N55
It is not possible to separate control module and hydraulic unit.
3. Brake line
^ To right front brake caliper
^ Identification: Dia. 5.25 mm and tube fitting with thread M 10 x 1
^ Marked on hydraulic unit with "VR"
4. Brake line
^ To left rear brake caliper
^ Identification: Dia. 5.25 mm and tube fitting with shorter thread M12 x 1
^ Marked on hydraulic unit with "HL"
5. Brake line
^ To right rear brake caliper
^ Identification: Dia. 5.25 mm and tube fitting with thread M 10 x 1
^ Marked on hydraulic unit with "HR"
6. Brake line
^ To left front brake caliper
^ Identification: Dia. 5.25 mm and tube fitting with shorter thread M12 x 1
^ Marked on hydraulic unit with "VL"
7. Brake line
^ Master brake cylinder/primary piston circuit to hydraulic control unit
^ Identification: Dia. 8.5 mm or dia. 6 mm and tube fitting with longer thread M12 x 1
^ Marked on hydraulic unit with "HZ1"
8. Brake line
^ Master brake cylinder/secondary piston circuit to hydraulic unit
^ Identification: Dia. 8.5 mm or dia. 6 mm and tube fitting with longer thread M12 x 1
^ Marked on hydraulic unit with "HZ2"
9. Heat shield
10. Inner Torx(R) bolt, 12 Nm
11. Brake booster
^ On vehicles with HBV, a vacuum sensor is installed
12. Console
13. Hex nut, tighten to 20 Nm
14. Rubber insulation
15. Inner Torx(R) bolt, 10 Nm
16. Bracket
Connecting brake lines from dual master brake cylinder to hydraulic unit
On tandem brake master cylinder:
A - Master cylinder primary piston circuit to hydraulic unit
- Identification: Dia. 8.5 mm or dia. 6 mm and tube fitting with thread M12 x 1
B - Master cylinder secondary piston circuit to hydraulic unit
- Identification: Dia. 8.5 mm or dia. 6 mm and tube fitting with thread M12 x 1
1 - Hydraulic unit to left front brake caliper
3 - Hydraulic unit to left rear brake caliper
4 - Hydraulic unit to right rear brake caliper
On hydraulic unit:
1. Hydraulic unit to left front brake caliper
- Identification: Dia. 5.25 mm and tube fitting with shorter thread M12 x 1
2. Hydraulic control unit to right rear brake caliper
- Identification: Dia. 5.25 mm and tube fitting with thread M10 x 1
3. Hydraulic control unit to left rear brake caliper
- Identification: Dia. 5.25 mm and tube fitting with shorter thread M12 x 1
4. Hydraulic unit to right front brake caliper
- Identification: Dia. 5.25 mm and tube fitting with thread M10 x 1
5. Hydraulic unit to master cylinder primary piston circuit
- Identification: Dia. 8.5 mm or dia. 6 mm and tube fitting with longer thread M12 x 1
6. Hydraulic unit to master cylinder secondary piston circuit
- Identification: Dia. 8.5 mm or dia. 6 mm and tube fitting with longer thread M12 x 1
Control module and hydraulic unit, removing
Special tools, testers and auxiliary items required
^ Torque wrench V.A.G 1331
^ Torque wrench V.A.G 1410
^ Brake pedal actuator V.A.G 1869/2
Sealing plug repair kit, part no. 1 H0 698 311 A
1 - Transport protection for valve body (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 engine compartment.
CAUTION: Do not bend brake lines near the hydraulic unit!
- Read out and note present control module coding.
- Note or request radio code on vehicles with coded radio if necessary.
- Disconnect battery.
- Remove engine cover.
- Disconnect knock sensor and vacuum hose valve connectors at rear of intake manifold. Unclip wiring harness from retainers on coolant pipe and lay it aside.
- Remove vacuum hoses on rear of intake manifold, remove from retainers and set aside completely.
- Loosen right rear coolant pipe from left and rear of engine.
- Disconnect both coolant hoses on reservoir with Hose clamps up to 25 mm dia. 3094.
- Remove both coolant hoses on reservoir and then set them as far aside as possible with coolant pipe.
- On vehicles with heat shield, remove heat shield.
- Press red securing clip in direction of - arrow - toward the rear.
- Release and remove connector from control module in direction of - arrow-.
- Install brake pedal actuator 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.
- Depress brake pedal at least 60 mm using brake pedal actuator V.A.G 1869/2.
- Close left front and left rear bleeder valves.
- Do not remove brake pedal actuator V.A.G 1869/2.
- Place sufficient lint-free cloths under control module and hydraulic unit.
Make sure that brake fluid does not come in contact with terminals.
- First, mark both brake lines from master cylinder and remove from hydraulic unit.
- Plug brake lines and threaded holes immediately with sealing plugs from repair kit Part No. 1 H0 698 311 A.
- Mark, unfasten and plug remaining brake lines (brake calipers).
- Lift hydraulic unit with control module up and out of dampers - arrow -.
Control module and hydraulic unit, installing
Note:
^ Do not remove sealing plugs on 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 the hydraulic unit, make sure the damper rubber is not pushed out of the console.
- Installation is in reverse order of removal.
Fastening sequence of brake lines:
- Remove brake pedal actuator V.A.G 1869/2.
- Bleed braking system.
- Enter radio code.
- Perform ABS Control Module J104 coding using in "Guided Fault Finding".
A Steering Angle Sensor G85, Transverse Acceleration Sensor G200, Longitudinal Acceleration Sensor G251 and Brake Pressure Sensor 1 G201 basic setting must be done.
Tightening torques:
