ABS Control Module and ABS Hydraulic Unit
ABS Control Module and ABS Hydraulic Unit
With a diesel particulate filter
• Beginning with MY 09, the ESP sensor unit (G419) is inside the ABS control module (J104).
• Beginning with MY 09, the ABS control module must be replaced if the ESP sensor unit is faulty.
• Beginning with MY 09, the ABS control module must be calibrated if it was replaced.
• Beginning with MY 09, the steering angle and the braking pressure are stored in the ABS control module and must be calibrated.
On the Mark 60 EC system
If the Mark 60EC ABS control module is being replaced, then it will be necessary to perform a basic setting to the intake and the separating valves. Refer to => [ Intake Valves and Separating Valves, Mark60EC, Basic Setting ] Programming and Relearning
Use the vehicle diagnosis, testing and information system (VAS 5051 B) or (VAS 5052).
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. 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 plugs M10 for brake lines and threaded bores
3 Sealing plugs M12 for brake lines and threaded bores
Removing
- Install the (V.A.G 1869/2) between the brake pedal and driver seat. Depress the brake pedal a minimum of 60 mm.
- Connect the hose of a bleeder bottle to the bleeder screws of the left front and left rear brake calipers, and open the bleeder screws.
• This lowers the pressure in the hydraulic unit.
- Close the left front and left rear bleeder screws.
- Do not remove (V.A.G 1869/2).
- Remove the engine cover - 1 and 2 -.
- Disconnect the air guide for the turbocharger and move it to the side.
- Release control module harness connector - arrow 1 - and pull off - arrow 2 -.
• Make sure that no brake fluid gets into the control module connector housing. This could lead to corrosion of the contacts and thereby cause the system to fail.
• Clean a dirty connector housing thoroughly with compressed air.
- To protect against escaping brake fluid, place a lint-free rag in the area under the control module and hydraulic unit.
- Mark the brake lines.
- Disconnect the tie up the brake lines on the hydraulic unit - 1 - leading to the master brake cylinder.
- Disconnect the remaining brake lines - 2 - from the hydraulic unit.
Do not bend the brake lines near the hydraulic unit.
- Seal the brake lines and threaded bores with sealing plugs from the repair kit.
- Pry the hydraulic unit with control module upward and off, see - arrows -.
- Remove the bolts on the hydraulic unit mount - 1 -; tightening specification: 8 Nm.
Unfastening control module from hydraulic unit
- Set hydraulic unit with control module downward onto a clean, level surface.
- Remove internal Torx(R) bolts - arrows - from the hydraulic pump.
The hydraulic pump must not be separated from the hydraulic unit.
- For this reason, secure hydraulic pump to hydraulic unit using red retainer - 1 - from replacement part kit 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, contaminated 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 inner Torx(R) 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.
• Do not install a used control module.
- Remove the bolt - 1 -.
- Unclip line - 2 -.
- Remove nut - 1 -, Tightening specification: 20 Nm.
Installing
Installation is in reverse order of removal, with special attention to the following:
• 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.
- When fitting together the control module and hydraulic unit, make sure that the valve body of the hydraulic unit does not bind with the solenoid coils of the control module.
- Connect the lines according to the markings. Refer to => [ Control Module and Hydraulic Unit, ABS/ESP ITT Mark 60 ] Control Module and Hydraulic Unit, ABS/ESP ITT Mark 60.
- Fasten the ABS unit to the bracket.
• Do not tighten bolts completely. This makes it easier to fasten the individual brake lines to the hydraulic unit.
- Tighten all brake lines.
- After fastening the brake lines, fasten the hydraulic unit.
- Install the air guide for the turbocharger.
- Install the engine cover - 1 and 2 -.
- Bleed the brake system. Refer to => [ Bleeding Brake System, ITT ABS/ESP Mark 60/ABS Mark 70 ] Bleeding Brake System, ITT ABS/ESP Mark 60/ABS Mark 70.
- If the control module was replaced, it must be coded.
Use the vehicle diagnosis, testing and information system (VAS 5051 B) or (VAS 5052).
- Connect the vehicle diagnosis, testing, and information system and select the function test using functions/component selection. Refer to => [ VAS 5951 B or VAS 5052, Connecting and Selecting Functions ] Scan Tool Testing and Procedures.
Then
- "Chassis"
- "Brake System"
- "01- On Board Diagnostic (OBD) capable systems"
- "J104- ABS/ASR/ESP Control Module Mark 60"
- "J104- ABS/ASR/ESP Control Module, Functions"
- "J104- Control module, coding"
- After fastening the brake lines to the ABS hydraulic unit, perform the output check diagnosis. Vehicle diagnosis, testing and information system (VAS 5051 B) or (VAS 5052)
• If the ABS control module (J104) is replaced, the following sensors must be calibrated:
• Steering angle sensor (G85)
• Transverse acceleration sensor (G200)
• Brake pressure sensor 1 (G201)
• Longitudinal acceleration sensor (G251) (only equipped on all-wheel drive vehicles)
• Beginning with MY 09, the steering angle and the braking pressure are stored in the ABS control module and must be calibrated.
• Afterwards, the ESP driving and system tests must be performed.
Use the vehicle diagnosis, testing and information system (VAS 5051 B) or (VAS 5052).
- Connect (VAS 5051 B) or (VAS 5052) and select function/component selection. Refer to => [ VAS 5951 B or VAS 5052, Connecting and Selecting Functions ] Scan Tool Testing and Procedures.
- "Chassis"
- "Brake System"
- "01- On Board Diagnostic (OBD) capable systems"
- "J104- ABS/ASR/ESP Control Module Mark 60"
- "J104- ABS/ASR/ESP Control Module, Functions"
On the Mark 60EC system
If the Mark 60EC ABS control module is being replaced, then it will be necessary to perform a basic setting to the intake and the separating valves. Refer to=> [ Intake Valves and Separating Valves, Mark60EC, Basic Setting ] Programming and Relearning
Use the vehicle diagnosis, testing and information system (VAS 5051 B) or (VAS 5052).
• By performing the output check diagnosis, it can be determined if the line connections were interchanged.
Tightening Specifications
Replace bolts